Perkins 400D Owners Manual

SEBU8311-01April 2008

Operation andMaintenanceManual402D-403D-404D Industrial EngineGG (Engine)GH (Engine)GJ (Engine)GK (Engine)GL (Engine)GM (Engine)GN (Engine)GP (Engine)GQ (Engine)GS (Engine)

This document has been printed from SPI². Not for Resale

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure toobserve basic safety rules or precautions. An accident can often be avoided by recognizing potentiallyhazardous situations before an accident occurs. A person must be alert to potential hazards. Thisperson should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazardwarnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written orpictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. Thewarnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,work method or operating technique that is not specifically recommended by Perkins is used,you must satisfy yourself that it is safe for you and for others. You should also ensure that theproduct will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information beforeyou start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for thisproduct Perkins recommends using Perkins replacement parts.Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.


SEBU8311-01 3Table of Contents

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 5

General Hazard Information ................................... 7

Burn Prevention ...................................................... 8

Fire Prevention and Explosion Prevention .............. 8

Crushing Prevention and Cutting Prevention ........ 10

Before Starting Engine ........................................... 11

Engine Starting ...................................................... 11

Engine Stopping .................................................... 11

Electrical System .................................................. 12

Product Information Section

Model Views ......................................................... 13

Product Identification Information ........................ 23

Operation Section

Lifting and Storage ................................................ 25

Gauges and Indicators .......................................... 28

Features and Controls .......................................... 29

Engine Starting ..................................................... 30

Engine Operation .................................................. 33

Engine Stopping ................................................... 34

Cold Weather Operation ....................................... 35

Maintenance Section

Refill Capacities .................................................... 39

Maintenance Interval Schedule ............................ 58

Warranty Section

Warranty Information ............................................ 89

Index Section

Index ..................................................................... 90


4 SEBU8311-01Foreword

ForewordLiterature InformationThis manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.

English is the primary language for all Perkinspublications. The English used facilitates translationand consistency.

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Perkins dealer or your Perkinsdistributor for the latest available information.

SafetyThis safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance andrepair on this product.

OperationOperating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.

MaintenanceThe maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby service hours and/or calendar time maintenanceintervals. Items in the maintenance schedule arereferenced to detailed instructions that follow.

Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.

The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.

Maintenance IntervalsPerform maintenance on items at multiples ofthe original requirement. We recommend that themaintenance schedules be reproduced and displayednear the engine as a convenient reminder. We alsorecommend that a maintenance record be maintainedas part of the engine’s permanent record.

Your authorized Perkins dealer or your Perkinsdistributor can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.

OverhaulMajor engine overhaul details are not covered inthe Operation and Maintenance Manual exceptfor the interval and the maintenance items in thatinterval. Major repairs should only be carried out byPerkins authorized personnel. Your Perkins dealeror your Perkins distributor offers a variety of optionsregarding overhaul programs. If you experiencea major engine failure, there are also numerousafter failure overhaul options available. Consult withyour Perkins dealer or your Perkins distributor forinformation regarding these options.

California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm. Batteryposts, terminals and related accessories contain leadand lead compounds.Wash hands after handling.


SEBU8311-01 5Safety Section

Safety Messages

Safety Sectioni02959960

Safety Messages

There may be several specific warning signs on yourengine. The exact location and a description of thewarning signs are reviewed in this section. Pleasebecome familiar with all warning signs.

Ensure that all of the warning signs are legible. Cleanthe warning signs or replace the warning signs ifthe words cannot be read or if the illustrations arenot visible. Use a cloth, water, and soap to cleanthe warning signs. Do not use solvents, gasoline, orother harsh chemicals. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures thewarning signs. The warning signs that are loosenedcould drop off of the engine.

Replace any warning sign that is damaged ormissing. If a warning sign is attached to a part of theengine that is replaced, install a new warning sign onthe replacement part. Your Perkins dealer or yourdistributor can provide new warning signs.

(A) Universal Warning

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions orheed the warnings could result in serious injuryor death.

g01154807Illustration 1

Typical example

Warning label (A) is installed in different locations.The location will change according to the physicalsize of the engine.


6 SEBU8311-01Safety SectionSafety Messages

g01324126Illustration 2(A) Location of warning label(1) 402D-05(2) 403D-07

(3) 403D-11(4) 403D-15, 403D-15T and 403D-17(5) 404D-15

(6) 404D-22, 404D-22T and 404D-22TA



General Hazard Information

i02328435

General Hazard Information


Attach a “Do Not Operate” warning tag or a similarwarning tag to the start switch or to the controlsbefore you service the equipment or before yourepair the equipment.


Wear a hard hat, protective glasses, and otherprotective equipment, as required.

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine.

Make sure that all protective guards and all coversare secured in place on the engine.

Keep the engine free from foreign material. Removedebris, oil, tools, and other items from the deck, fromwalkways, and from steps.

Never put maintenance fluids into glass containers.Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Report all necessary repairs.

Do not allow unauthorized personnel on theequipment.

Ensure that the power supply is disconnected beforeyou work on the bus bar or the glow plugs.

Perform maintenance on the engine with theequipment in the servicing position. Refer to theOEM information for the procedure for placing theequipment in the servicing position.

Pressure Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

The direct application of pressurized air orpressurized water to the body could result in personalinjury.

When pressurized air and/or water is used forcleaning, wear protective clothing, protective shoes,and eye protection. Eye protection includes gogglesor a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must be below275 kPa (40 psi).

Fluid PenetrationPressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the OEMinformation for any procedures that are required torelieve the hydraulic pressure.


8 SEBU8311-01Safety SectionBurn Prevention


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theengine. Make provision to collect the fluid with asuitable container before any compartment is openedor before any component is disassembled.

• Only use the tools that are suitable for collectingfluids and equipment that is suitable for collectingfluids.

• Only use the tools that are suitable for containingfluids and equipment that is suitable for containingfluids.

Obey all local regulations for the disposal of liquids.

i02143195

Burn Prevention

Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level after the engine has stoppedand the engine has been allowed to cool.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

i02813488

Fire Prevention and ExplosionPrevention




Fire Prevention and Explosion Prevention

All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.

Determine whether the engine will be operated in anenvironment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.

If the application involves the presence of combustiblegases, consult your Perkins dealer and/or yourPerkins distributor for additional information aboutsuitable protection devices.

Remove all flammable combustible materials orconductive materials such as fuel, oil, and debris fromthe engine. Do not allow any flammable combustiblematerials or conductive materials to accumulate onthe engine.

Store fuels and lubricants in correctly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in case of a line,a tube, or a seal failure. Exhaust shields must beinstalled correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding or flame cutting.

Wiring must be kept in good condition. All electricalwires must be correctly routed and securely attached.Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate theengine. Clean all electrical connections and tightenall electrical connections.

Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and correctlymaintained battery cables will help to prevent arcingor sparking.

Inspect all lines and hoses for wear or fordeterioration. The hoses must be correctly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.

Oil filters and fuel filters must be correctly installed.The filter housings must be tightened to the correcttorque.


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.


10 SEBU8311-01Safety SectionCrushing Prevention and Cutting Prevention


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Incorrect jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

The batteries must be kept clean. The covers(if equipped) must be kept on the cells. Use therecommended cables, connections, and battery boxcovers when the engine is operated.

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged. Do not clip any other items to the highpressure lines.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Perkins dealer or yourPerkins distributor for repair or for replacement parts.

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

i02143194

Crushing Prevention andCutting Prevention

Support the component correctly when work beneaththe component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

Stay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.

Keep objects away from moving fan blades. The fanblades will throw objects or cut objects.

When objects are struck, wear protective glasses inorder to avoid injury to the eyes.

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.



Before Starting Engine

i02813489


Before the initial start-up of an engine that is new,serviced or repaired, make provision to shut theengine off, in order to stop an overspeed. This maybe accomplished by shutting off the air and/or fuelsupply to the engine.

Overspeed shutdown should occur automatically forengines that are controlled electronically. If automaticshutdown does not occur, press the emergency stopbutton in order to cut the fuel and/or air to the engine.

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. Ensure that thearea is free of personnel.

If equipped, ensure that the lighting system for theengine is suitable for the conditions. Ensure that alllights work correctly, if equipped.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.

See the Service Manual for repairs and foradjustments.

i02157354

Engine Starting

Do not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal injury.

If a warning tag is attached to the engine start switchor to the controls, DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operator’s compartment orfrom the engine start switch.

Always start the engine according to the procedurethat is described in the Operation and MaintenanceManual, “Engine Starting” topic in the OperationSection. Knowing the correct procedure will help toprevent major damage to the engine components.Knowing the procedure will also help to preventpersonal injury.

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingcorrectly, check the water temperature gauge and theoil temperature gauge during the heater operation.

Engine exhaust contains products of combustionwhich can be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is started in an enclosed area,vent the engine exhaust to the outside.

Note: The engine is equipped with an automaticdevice for cold starting for normal conditions ofoperation. If the engine will be operated in very coldconditions, then an extra cold starting aid may berequired. Normally, the engine will be equipped withthe correct type of starting aid for your region ofoperation.

The 400 Series engines are equipped with a glowplug starting aid in each individual cylinder that heatsthe intake air in order to improve starting.

i02590389

Engine Stopping

To avoid overheating of the engine and acceleratedwear of the engine components, stop the engineaccording to this Operation and Maintenance Manual,“Engine Stopping” topic (Operation Section).

Use the Emergency Stop Button (if equipped)ONLY in an emergency situation. DO NOT use theEmergency Stop Button for normal engine stopping.After an emergency stop, DO NOT start the engineuntil the problem that caused the emergency stophas been corrected.


12 SEBU8311-01Safety SectionElectrical System

On the initial start-up of a new engine or an enginethat has been serviced, make provisions to stop theengine if an overspeed condition occurs. This may beaccomplished by shutting off the fuel supply and/orthe air supply to the engine.

If equipped, in order to stop an electronicallycontrolled engine, cut the power to the engine.

i02176668

Electrical System

Never disconnect any charging unit circuit or batterycircuit cable from the battery when the charging unitis operating. A spark can cause the combustiblegases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative “−” jump start cable should be connectedlast from the external power source to the negative“−” terminal of the starting motor. If the starting motoris not equipped with a negative “−” terminal, connectthe jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. Seethe Operation and Maintenance Manual for specificstarting instructions.

Grounding PracticesCorrect grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Incorrect grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

To ensure that the engine and the engine electricalsystems function correctly, an engine-to-frameground strap with a direct path to the battery must beused. This path may be provided by way of a directengine ground to the frame.

All grounds should be tight and free of corrosion. Theengine alternator must be grounded to the negative“-” battery terminal with a wire that is adequate tohandle the full charging current of the alternator.


SEBU8311-01 13Product Information Section

Model Views

Product InformationSection

Model Viewsi02590436

Model View Illustrations

The following model views show typical featuresof the 400 series engines. Due to individualapplications, your engine may appear different fromthe illustrations.

Note: Individual components are detailed on the404D-22T turbocharged engine only.

g01299985Illustration 9Typical view of the 402D-05 engine


14 SEBU8311-01Product Information SectionModel Views


Typical view of the 403D-15T engine



Model Views


Front and right side view of the 404D-22T Engine(1) Fuel shutoff solenoid(2) Number one fuel injector(3) Water pump(4) Lower engine oil filler cap

(5) Throttle lever(6) Cover plate for the accessory drive(7) Engine oil level gauge(8) Engine oil cooler

(9) Engine oil filter(10) Fuel injection pump(11) Transfer pump(12) Fuel filter




Front and left side view of the 404D-22T Engine(13) Top engine oil filler cap(14) Crankcase breather(15) Rear Lifting eye(16) Air inlet elbow(17) Valve mechanism cover(18) Turbocharger

(19) Water temperature regulator housing(20) Starting motor solenoid(21) Electric starting motor(22) Alternator(23) Engine oil pan(24) Engine oil drain plug

(25) Fan drive belt(26) Crankshaft pulley(27) Coolant temperature switch(28) Cooling fan

i02959055

Engine Description

The 400 series engines are indirect injection engines.The engines are controlled with a mechanicallyactuated fuel injection pump. The engine cylindersare arranged in-line.

The cylinder head assembly has one inlet valve andone exhaust valve for each cylinder. Each cylindervalve has a single valve spring.

The pistons have two compression rings and anoil control ring. It is important to ensure the correctpiston height so that the piston does not contact thecylinder head. The correct piston height also ensuresefficient combustion of fuel that is necessary in orderto conform to requirements for emissions.

The crankshaft for a two cylinder engine has twomain bearing journals. The crankshaft for a threecylinder engine has four main bearing journals. Thecrankshaft for a four cylinder engine has five mainbearing journals. End play is controlled by the thrustwashers that are located on the rear main bearing.



Model Views

The timing gears are stamped with timing marks inorder to ensure the correct assembly of the gears.When the No. 1 piston is at top center compressionstroke, the teeth that are stamped on the crankshaftgear and the camshaft gear will be in alignment withthe idler gear.

The crankshaft gear turns the idler gear which thenturns the camshaft gear and the gear for the engineoil pump.

The fuel injection pump is mounted in the cylinderblock. The fuel injection pump is operated by lobeson the camshaft. The fuel transfer pump is locatedon the right hand side of the cylinder block. Thefuel transfer pump is also operated by lobes on thecamshaft.

The fuel injection pump conforms to requirementsfor emissions. If any adjustments to the fuel injectionpump timing and high idle are required you mustrefer to your Perkins distributoror your Perkinsdealer. Some fuel injection pumps have mechanicalgovernors that control the engine rpm. Some fuelinjection pumps have a governor that is electricallycontrolled.

A gerotor oil pump is located in the center of the idlergear. The engine oil pump sends lubricating oil to themain oil gallery through a pressure relief valve and anengine oil filter. The rocker arms receive pressurizedoil through an externally located oil line that runs fromthe main oil gallery to the cylinder head.

Coolant from the bottom of the radiator passesthrough the belt driven centrifugal water pump. Thecoolant is cooled by the radiator and the temperatureis regulated by a water temperature regulator.

Engine efficiency, efficiency of emission controls, andengine performance depend on adherence to correctoperation and maintenance recommendations.Engine performance and efficiency also depend onthe use of recommended fuels, lubrication oils, andcoolants. Refer to the Operation and MaintenanceManual, “Maintenance Interval Schedule” for moreinformation on maintenance items.

Engine SpecificationsNote: The front end of the engine is opposite theflywheel end of the engine. The left and the right sideof the engine are determined from the flywheel end.The No. 1 cylinder is the front cylinder.



402D-05 Engine


(A) Exhaust valves(B) Inlet valves

Table 1

402D-05 Engine Specifications

Maximum OperatingSpeed (rpm) 3600 rpm

Cylinders andArrangement In-Line two cylinder

Bore 67 mm (2.64 inch)

Stroke 72 mm (2.83 inch)

Displacement 0.507 L (30.939 in3)

Aspiration NA(1)

Compression Ratio 23.5:1

Firing Order 1-2

Rotation that is viewedfrom the flywheel Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting(Exhaust) 0.20 mm (0.008 inch)

Injection Indirect(1) Naturally Aspirated

403D-07 Engine



Table 2



Cylinders andArrangement In-Line three cylinder




Aspiration NA(1)


Firing Order 1-2-3







Model Views

403D-11 Engine



Table 3







Aspiration NA(1)

Compression Ratio 23:1

Firing Order 1-2-3





403D-15 Engine



Table 4







Aspiration NA(1)


Firing Order 1-2-3







403D-15T Engine



Table 5

403D-15T Engine Specifications






Aspiration T(1)


Firing Order 1-2-3




Injection Indirect(1) Turbocharged

403D-17 Engine



Table 6







Aspiration NA(1)


Firing Order 1-2-3







Model Views

404D-15 Engine



Table 7



Cylinders andArrangement In-Line four cylinder




Aspiration NA(1)


Firing Order 1-3-4-2





404D-22 Engine



Table 8




Bore 84.0 mm (3.31 inch)

Stroke 100.0 mm (3.94 inch)


Aspiration NA(1)









404D-22T Engine



Table 9

404D-22T Engine Specifications






Aspiration T(1)






Injection Indirect(1) Turbocharged

404D-22TA Engine



Table 10

404D-22TA Engine Specifications






Aspiration TA(1)






Injection Indirect(1) Turbocharged aftercooled



Product Identification Information

Product IdentificationInformation

i02643641

Engine Identification

Perkins engines are identified by a serial number.This number is shown on a serial number plate thatis mounted above the fuel injection pump on the righthand side of the engine block.

An example of an engine number isGP*****U000001M.

GP _________________________________________Type of engine

U ____________________________Built in the United Kingdom

*****______________________The list number of the engine

000001 ___________________________Engine Serial Number

M ____________________________________Year of Manufacture

Perkins dealers or Perkins distributors need all ofthese numbers in order to determine the componentsthat were included with the engine. This permitsaccurate identification of replacement part numbers.

i02157258

Serial Number Plate


Typical serial number plate

The Serial Number Plate is located above the fuelinjection pump on the right side of the cylinder block.

The following information is stamped on the SerialNumber Plate: Engine serial number, Model, andArrangement number.

i02164876

Reference Numbers

Information for the following items may be needed toorder parts. Locate the information for your engine.Record the information in the appropriate space.Make a copy of this list for a record. Keep theinformation for future reference.

Record for ReferenceEngine Model _______________________________________________

Engine Serial number _____________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

Primary Fuel Filter _________________________________________

Water Separator Element ________________________________

Secondary Fuel Filter Element __________________________

Lubrication Oil Filter Element ___________________________

Auxiliary Oil Filter Element _______________________________

Total Lubrication System Capacity _____________________

Total Cooling System Capacity _________________________

Air Cleaner Element _______________________________________

Fan Drive Belt ______________________________________________

Alternator Belt ______________________________________________


24 SEBU8311-01Product Information SectionProduct Identification Information

i02959144

Emissions Certification Film

g01478138Illustration 24Typical example


Typical example

Perkins Shibaura Engines Limited will supply thefuel label with every engine. Refer to illustration25. The equipment manufacturer must install thelabel to the equipment. This is recommended byPerkins Shibaura Engines Limited. The label must beattached to the equipment near the fuel inlet. Thiswill comply with the EPA regulations. The equipmentmanufacturer may install another fuel label. If anotherfuel label is used, the equipment manufacturer mustsend a drawing or a photo of the label to PerkinsShibaura Engines Limited through the PerkinsDistributor. This will ensure compliance of the label.


SEBU8311-01 25Operation SectionLifting and Storage

Operation Section

Lifting and Storagei02164186

Engine Lifting


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) should beparallel to each other. The chains and cables shouldbe perpendicular to the top of the object that is beinglifted.

Some removals require lifting the fixtures in order toobtain correct balance and safety.

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for specificengine arrangements. Alterations to the lifting eyesand/or the engine make the lifting eyes and the liftingfixtures obsolete. If alterations are made, ensurethat correct lifting devices are provided. Consultyour Perkins dealer or your Perkins distributor forinformation regarding fixtures for correct enginelifting.

i02593735

Engine Storage

If the engine will not be started for several weeks, thelubricating oil will drain from the cylinder walls andfrom the piston rings. Rust can form on the cylinderwalls. Rust on the cylinder walls will cause increasedengine wear and a reduction in engine service life.

Lubrication SystemTo help prevent excessive engine wear, use thefollowing guidelines:

Complete all of the lubrication recommendations thatare listed in this Operation and Maintenance Manual,“Maintenance Interval Schedule” (MaintenanceSection).

If an engine is out of operation and if use of the engineis not planned, special precautions should be made.If the engine will be stored for more than one month,a complete protection procedure is recommended.

Use the following guidelines :

• Completely clean the outside of the engine.

• Drain the fuel system completely and refillthe system with preservative fuel. 1772204POWERPART Lay-Up 1 can be mixed withthe normal fuel in order to change the fuel intopreservative fuel.

• If preservative fuel is not available, the fuel systemcan be filled with normal fuel. This fuel must bediscarded at the end of the storage period togetherwith the fuel filter elements.

• Operate the engine until the engine reaches normaloperating temperature. Stop any leaks from fuel,lubricating oil or air systems. Stop the engine anddrain the lubricating oil from the oil pan.


26 SEBU8311-01Operation SectionLifting and Storage

• Renew the canister(s) of the lubricating oil filter.

• Fill the oil pan to the Full Mark on the engine oillevel gauge with new, clean lubricating oil. Add1762811 POWERPART Lay-Up 2 to the oil inorder to protect the engine against corrosion. If1762811 POWERPART Lay-Up 2 is not available,use a preservative of the correct specificationinstead of the lubricating oil. If a preservative isused, this must be drained completely at the end ofthe storage period and the oil pan must be refilledto the correct level with normal lubricating oil.

Cooling SystemTo help prevent excessive engine wear, use thefollowing guidelines:

NOTICEDo not drain the coolant while the engine is still hot andthe system is under pressure because dangerous hotcoolant can be discharged.

If freezing temperatures are expected, check thecooling system for adequate protection againstfreezing. Refer to this Operation and MaintenanceManual, “Fluid Recommendations” (MaintenanceSection).

NOTICETo prevent frost damage, ensure that all the coolant isremoved from the engine. This is important if the sys-tem is drained after it has been flushed with water, or ifan antifreeze solution too weak to protect the systemfrom frost has been used.


1. Ensure that the vehicle is on level ground.

2. Remove the filler cap of the cooling system.

3. Remove the drain plug (1) from the side of thecylinder block in order to drain the engine. Ensurethat the drain hole is not restricted.

4. Open the tap or remove the drain plug at thebottom of the radiator in order to drain the radiator.If the radiator does not have a tap or a drain plug,disconnect the hose at the bottom of the radiator.

5. Flush the cooling system with clean water.

6. Fit the drain plugs and the filler cap. Close the tapor connect the radiator hose.

7. Fill the cooling system with an approved antifreezemixture because this gives protection againstcorrosion.

Note: Certain corrosion inhibitors could causedamage to some engine components. Contact theService Department of Perkins for advice.

8. Operate the engine for a short period in order tocirculate the lubricating oil and the coolant in theengine.

9. Disconnect the battery. Put the battery into safestorage in a fully charged condition. Before thebattery is put into storage, protect the terminalsagainst corrosion. 1734115 POWERPARTLay-Up 3 can be used on the terminals.

10.Clean the crankcase breather if one is installed.Seal the end of the pipe.

11.Remove the fuel injectors and spray 1762811POWERPART Lay-Up 2 for one or two secondsinto each cylinder bore with the piston at BDC.

12.Slowly rotate the crankshaft for one completerevolution and then replace the fuel injectors.

Induction System• Remove the air filter assembly. If necessary,remove the pipes that are installed betweenthe air filter assembly and the turbocharger.Spray 1762811 POWERPART Lay-Up 2 into theturbocharger. The duration of the spray is printedon the container. Seal the turbocharger withwaterproof tape.


SEBU8311-01 27Operation SectionLifting and Storage

Exhaust System• Remove the exhaust pipe. Spray 1762811POWERPART Lay-Up 2 into the turbocharger. Theduration of the spray is printed on the container.Seal the turbocharger with waterproof tape.

General Items• If the lubricating oil filler is installed on the valvemechanism cover, remove the filler cap. If thelubricating oil filler cap is not installed on the valvemechanism cover, remove the valve mechanismcover. Spray 1762811 POWERPART Lay-Up 2around the rocker shaft assembly. Replace thefiller cap or the valve mechanism cover.

• Seal the vent of the fuel tank or the fuel filler capwith waterproof tape.

• Remove the alternator drive belts and put the drivebelts into storage.

• In order to prevent corrosion, spray the engine with1734115 POWERPART Lay-Up 3. Do not spraythe area inside the alternator.

When the engine protection has been completed inaccordance with these instructions, this ensures thatno corrosion will occur. Perkins are not responsiblefor damage which may occur when an engine is instorage after a period in service.

Your Perkins dealer or your Perkins distributor canassist in preparing the engine for extended storageperiods.


28 SEBU8311-01Operation SectionGauges and Indicators

Gauges and Indicatorsi02216960

Gauges and Indicators

Your engine may not have the same gauges or all ofthe gauges that are described. For more informationabout the gauge package, see the OEM information.

Gauges provide indications of engine performance.Ensure that the gauges are in good working order.Determine the normal operating range by observingthe gauges over a period of time.

Noticeable changes in gauge readings indicatepotential gauge or engine problems. Problems mayalso be indicated by gauge readings that changeeven if the readings are within specifications.Determine and correct the cause of any significantchange in the readings. Consult your Perkins dealeror your Perkins distributor for assistance.

NOTICEIf no oil pressure is indicated, STOP the engine. Ifmaximum coolant temperature is exceeded, STOPthe engine. Engine damage can result.

Engine Oil Pressure – The oil pressureshould be greatest after a cold engine isstarted. The typical engine oil pressure with

SAE10W30 is 207 to 413 kPa (30 to 60 psi) at ratedrpm.

A lower oil pressure is normal at low idle. If the loadis stable and the gauge reading changes, performthe following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature –Typical temperature range is 71 to 96°C(160 to 205°F). The maximum allowable

temperature with the pressurized cooling systemat 90 kPa (13 psi) is 110°C (230°F). Highertemperatures may occur under certain conditions.The water temperature reading may vary accordingto load. The reading should never exceed the boilingpoint for the pressurized system that is being used.

If the engine is operating above the normal rangeand steam becomes apparent, perform the followingprocedure:

1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut downimmediately or if the engine can be cooled byreducing the load.

Tachometer – This gauge indicates enginespeed (rpm). When the throttle control leveris moved to the full throttle position without

load, the engine is running at high idle. The engine isrunning at the full load rpm when the throttle controllever is at the full throttle position with maximumrated load.

NOTICETo help prevent engine damage, never exceed thehigh idle rpm. Overspeeding can result in seriousdamage to the engine. The engine can be operatedat high idle without damage, but should never beallowed to exceed high idle rpm.

Ammeter – This gauge indicates theamount of charge or discharge in thebattery charging circuit. Operation of the

indicator should be to the right side of “0” (zero).

Fuel Level – This gauge indicates the fuellevel in the fuel tank. The fuel level gaugeoperates when the “START/STOP” switch

is in the “ON” position.

Service Hour Meter – The gauge indicatesoperating time of the engine.


SEBU8311-01 29Operation Section

Features and Controls

Features and Controlsi02593769

Fuel Shutoff

The fuel shutoff solenoid is located on the fuelinjection pump. When the fuel shutoff solenoid isactivated, the solenoid moves the fuel rack to the“OFF” position.

g01305771Illustration 28(1) Fuel shutoff solenoid

If an electronically controlled governor has beeninstalled the governor operates the fuel rack in orderto stop the engine.


30 SEBU8311-01Operation SectionEngine Starting

Engine Startingi02194223


Before the engine is started, perform the requireddaily maintenance and any other periodicmaintenance that is due. Refer to the Operationand Maintenance Manual, “Maintenance IntervalSchedule” for more information.

• For the maximum service life of the engine, make athorough inspection within the engine compartmentbefore the engine is started. Look for the followingitems: oil leaks, coolant leaks, loose bolts, andexcessive dirt and/or grease. Remove any excessdirt and/or grease buildup. Repair any faults thatwere identified during the inspection.

• Inspect the cooling system hoses for cracks andfor loose clamps.

• Inspect the alternator and accessory drive belts forcracks, breaks, and other damage.

• Inspect the wiring for loose connections and forworn wires or frayed wires.

• Check the fuel supply. Drain water from the waterseparator (if equipped). Open the fuel supply valve(if equipped).

NOTICEAll valves in the fuel return line must be open beforeand during engine operation to help prevent high fuelpressure. High fuel pressure may cause filter housingfailure or other damage.

If the engine has not been started for several weeks,fuel may have drained from the fuel system. Airmay have entered the filter housing. Also, when fuelfilters have been changed, some air pockets will betrapped in the engine. In these instances, prime thefuel system. Refer to the Operation and MaintenanceManual, “Fuel System - Prime” for more informationon priming the fuel system.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

• Do not start the engine or move any of the controlsif there is a “DO NOT OPERATE” warning tag orsimilar warning tag attached to the start switch orto the controls.

• Ensure that the areas around the rotating parts areclear.

• All of the guards must be put in place. Check fordamaged guards or for missing guards. Repairany damaged guards. Replace damaged guardsand/or missing guards.

• Disconnect any battery chargers that are notprotected against the high current drain thatis created when the electric starting motor isengaged. Check electrical cables and check thebattery for poor connections and for corrosion.

• Reset all of the shutoffs or alarm components (ifequipped).

• Check the engine lubrication oil level. Maintain theoil level between the “ADD” mark and the “FULL”mark on the engine oil level gauge.

• Check the coolant level. Observe the coolant levelin the header tank (if equipped). Maintain thecoolant level to the “FULL” mark on the headertank.

• If the engine is not equipped with a header tankmaintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel in the sight glass.

• Observe the air cleaner service indicator (ifequipped). Service the air cleaner when the yellowdiaphragm enters the red zone, or when the redpiston locks in the visible position.

• Ensure that any equipment that is driven by theengine has been disengaged from the engine.Minimize electrical loads or remove any electricalloads.

i02665533

Starting the Engine



SEBU8311-01 31Operation SectionEngine Starting

Refer to the OEM manual for your type of controls.Use the following procedure to start the engine.

1. Move the throttle lever to the low idle positionbefore you start the engine.

NOTICEDo not operate the glow plugs for more than 60 sec-onds at one time. Damage to the glow plugs could oc-cur.

2. Turn the engine start switch to the HEAT position.Hold the engine start switch in the HEAT positionfor 6 seconds until the glow plug indicator lightilluminates. This will activate the glow plugs andaid in the starting of the engine.

NOTICEDo not crank the engine for more than 30 seconds.Allow the electric starting motor to cool for twominutesbefore cranking the engine again.

3. While the glow plug indicator light is illuminated,turn the engine start switch to the START positionand crank the engine.

4. When the engine starts, release the engine startswitch.

5. Slowly move the throttle lever to the low idleposition and allow the engine to idle. Refer tothe Operation and Maintenance Manual, “AfterStarting Engine” topic.

Note: If the glow plug indicator light illuminatesrapidly for 2 to 3 seconds, or if the glow plug indicatorlight fails to illuminate, a malfunction exists in the coldstart system. Do not use ether or other starting fluidsto start the engine.

6. If the engine does not start, release the enginestart switch and allow the electric starting motor tocool. Then, repeat steps 2 through step 5.

7. Turn the engine start switch to the OFF position inorder to stop the engine.

i02177935

Starting with Jump StartCables

Improper jump start cable connections can causean explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jump startcable ends to contact each other or the engine.

Note: If it is possible, first diagnose the reasonfor the starting failure. Make any necessaryrepairs. If the engine will not start only due tothe condition of the battery, either charge thebattery, or start the engine with jump start cables.The condition of the battery can be recheckedafter the engine has been switched OFF.

NOTICEUsing a battery source with the same voltage as theelectric starting motor. Use ONLY equal voltage forjump starting. The use of higher voltage will damagethe electrical system.

Do not reverse the battery cables. The alternator canbe damaged. Attach ground cable last and removefirst.

When using an external electrical source to start theengine, turn the generator set control switch to the“OFF” position. Turn all electrical accessories OFF be-fore attaching the jump start cables.

Ensure that the main power switch is in the OFF posi-tion before attaching the jump start cables to the en-gine being started.

1. Turn the start switch to the OFF position. Turn offall the engine’s accessories.

2. Connect one positive end of the jump start cableto the positive cable terminal of the dischargedbattery. Connect the other positive end of the jumpstart cable to the positive cable terminal of theelectrical source.


32 SEBU8311-01Operation SectionEngine Starting

3. Connect one negative end of the jump start cableto the negative cable terminal of the electricalsource. Connect the other negative end of thejump start cable to the engine block or to thechassis ground. This procedure helps to preventpotential sparks from igniting the combustiblegases that are produced by some batteries.

4. Start the engine.

5. Immediately after the stalled engine is started,disconnect the jump start cables in reverse order.

After jump starting, the alternator may not be able tofully recharge batteries that are severely discharged.The batteries must be replaced or charged to thecorrect voltage with a battery charger after the engineis stopped. Many batteries which are consideredunusable are still rechargeable. Refer to Operationand Maintenance Manual, “Battery - Replace” andTesting and Adjusting Manual, “Battery - Test”.

i01903609

After Starting Engine

Note: In temperatures from 0 to 60°C (32 to 140°F),the warm-up time is approximately three minutes. Intemperatures below 0°C (32°F), additional warm-uptime may be required.

When the engine idles during warm-up, observe thefollowing conditions:

• Check for any fluid or for any air leaks at idle rpmand at one-half full rpm (no load on the engine)before operating the engine under load. This is notpossible in some applications.

• Operate the engine at low idle until all systemsachieve operating temperatures. Check all gaugesduring the warm-up period.

Note: Gauge readings should be observed andthe data should be recorded frequently while theengine is operating. Comparing the data over timewill help to determine normal readings for eachgauge. Comparing data over time will also helpdetect abnormal operating developments. Significantchanges in the readings should be investigated.


SEBU8311-01 33Operation SectionEngine Operation

Engine Operationi02176671

Engine Operation

Correct operation and maintenance are key factorsin obtaining the maximum life and economy ofthe engine. If the directions in the Operation andMaintenance Manual are followed, costs can beminimized and engine service life can be maximized.

The engine can be operated at the rated rpm after theengine reaches operating temperature. The enginewill reach normal operating temperature soonerduring a low engine speed (rpm) and during a lowpower demand. This procedure is more effective thanidling the engine at no load. The engine should reachoperating temperature in a few minutes.

Gauge readings should be observed and the datashould be recorded frequently while the engineis operating. Comparing the data over time willhelp to determine normal readings for each gauge.Comparing data over time will also help detectabnormal operating developments. Significantchanges in the readings should be investigated.

i02330149

Fuel Conservation Practices

The efficiency of the engine can affect the fueleconomy. Perkins design and technology inmanufacturing provides maximum fuel efficiency inall applications. Follow the recommended proceduresin order to attain optimum performance for the lifeof the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuelmay overflow from the fuel tank. Inspect fuel lines forleaks. Repair the fuel lines, as needed.

• Be aware of the properties of the different fuels.Use only the recommended fuels.

• Avoid unnecessary idling.

Shut off the engine rather than idle for long periods oftime.

• Observe the air cleaner service indicator frequently.Keep the air cleaner elements clean.

• Maintain the electrical systems.

One damaged battery cell will overwork the alternator.This will consume excess power and excess fuel.

• Ensure that the drive belts are correctly adjusted.The drive belts should be in good condition.

• Ensure that all of the connections of the hoses aretight. The connections should not leak.

• Ensure that the driven equipment is in goodworking order.

• Cold engines consume excess fuel. Utilize heatfrom the jacket water system and the exhaustsystem, when possible. Keep cooling systemcomponents clean and keep cooling systemcomponents in good repair. Never operate theengine without water temperature regulators.All of these items will help maintain operatingtemperatures.


34 SEBU8311-01Operation SectionEngine Stopping

Engine Stoppingi02334873

Stopping the Engine

NOTICEStopping the engine immediately after it has beenworking under load, can result in overheating and ac-celerated wear of the engine components.

Avoid accelerating the engine prior to shutting it down.

Avoiding hot engine shutdowns will maximize tur-bocharger shaft and bearing life.

Note: Individual applications will have differentcontrol systems. Ensure that the shutoff proceduresare understood. Use the following general guidelinesin order to stop the engine.

1. Remove the load from the engine. Reduce theengine speed (rpm) to low idle. Allow the engineto idle for five minutes in order to cool the engine.

2. Stop the engine after the cool down periodaccording to the shutoff system on the engine andturn the ignition key switch to the OFF position.If necessary, refer to the instructions that areprovided by the OEM.

i01903586

Emergency Stopping

NOTICEEmergency shutoff controls are for EMERGENCY useONLY. DO NOT use emergency shutoff devices orcontrols for normal stopping procedure.

The OEM may have equipped the application withan emergency stop button. For more informationabout the emergency stop button, refer to the OEMinformation.

Ensure that any components for the external systemthat support the engine operation are secured afterthe engine is stopped.

i02176672

After Stopping Engine

Note: Before you check the engine oil, do not operatethe engine for at least 10 minutes in order to allowthe engine oil to return to the oil pan.

• Check the crankcase oil level. Maintain the oil levelbetween the “MIN” mark and the “MAX” mark onthe engine oil level gauge.

• If necessary, perform minor adjustments. Repairany leaks and tighten any loose bolts.

• If the engine is equipped with a service hour meter,note the reading. Perform the maintenance thatis in the Operation and Maintenance Manual,“Maintenance Interval Schedule”.

• Fill the fuel tank in order to help preventaccumulation of moisture in the fuel. Do not overfillthe fuel tank.

NOTICEOnly use antifreeze/coolant mixtures recommended inthe Coolant Specifications that are in the Operationand Maintenance Manual. Failure to do so can causeengine damage.

• Allow the engine to cool. Check the coolant level.

• If freezing temperatures are expected, checkthe coolant for correct antifreeze protection. Thecooling system must be protected against freezingto the lowest expected outside temperature. Addthe correct coolant/water mixture, if necessary.

• Perform all required periodic maintenance on alldriven equipment. This maintenance is outlined inthe instructions from the OEM.



Cold Weather Operation

Cold Weather Operationi02717265


Perkins Diesel Engines can operate effectively incold weather. During cold weather, the starting andthe operation of the diesel engine is dependent onthe following items:

• The type of fuel that is used

• The viscosity of the engine oil

• The operation of the glow plugs

• Optional Cold starting aid

• Battery condition

This section will cover the following information:

• Potential problems that are caused by cold weatheroperation

• Suggest steps which can be taken in order tominimize starting problems and operating problemswhen the ambient air temperature is between0° to−40 °C (32° to 40 °F).

The operation and maintenance of an engine infreezing temperatures is complex . This is becauseof the following conditions:

• Weather conditions

• Engine applications

Recommendations from your Perkins dealer oryour Perkins distributor are based on past provenpractices. The information that is contained inthis section provides guidelines for cold weatheroperation.

Hints for Cold Weather Operation• If the engine will start, operate the engine until aminimum operating temperature of 81 °C (177.8 °F)is achieved. Achieving operating temperature willhelp prevent the intake valves and exhaust valvesfrom sticking.

• The cooling system and the lubrication systemfor the engine do not lose heat immediately uponshutdown. This means that an engine can be shutdown for a period of time and the engine can stillhave the ability to start readily.

• Install the correct specification of engine lubricantbefore the beginning of cold weather.

• Check all rubber parts (hoses, fan drive belts, etc)weekly.

• Check all electrical wiring and connections for anyfraying or damaged insulation.

• Keep all batteries fully charged and warm.

• Fill the fuel tank at the end of each shift.

• Check the air cleaners and the air intake daily.Check the air intake more often when you operatein snow.

• Ensure that the glow plugs are in working order.Refer to Testing and Adjusting Manual, “Glow Plug- Test”.

Personal injury or property damage can resultfrom alcohol or starting fluids.

Alcohol or startingfluids are highly flammable andtoxic and if improperly stored could result in injuryor property damage.


• For jump starting with cables in cold weather,refer to the Operation and Maintenance Manual,“Starting with Jump Start Cables.” for instructions.

Viscosity of the Engine LubricationOilCorrect engine oil viscosity is essential. Oil viscosityaffects the amount of torque that is needed tocrank the engine. Refer to this Operation andMaintenance Manual, “Fluid Recommendations” forthe recommended viscosity of oil.

Recommendations for the CoolantProvide cooling system protection for the lowestexpected outside temperature. Refer to this Operationand Maintenance Manual, “Fluid Recommendations”for the recommended coolant mixture.


36 SEBU8311-01Operation SectionCold Weather Operation

In cold weather, check the coolant often for thecorrect glycol concentration in order to ensureadequate freeze protection.

Engine Block Heaters

Engine block heaters (if equipped) heat theengine jacket water that surrounds the combustionchambers. This provides the following functions:

• Startability is improved.

• Warm up time is reduced.

An electric block heater can be activated oncethe engine is stopped. An effective block heateris typically a 1250/1500 W unit. Consult yourPerkins dealer or your Perkins distributor for moreinformation.

Idling the EngineWhen idling after the engine is started in coldweather, increase the engine rpm from 1000 to 1200rpm. This will warm up the engine more quickly.Maintaining an elevated low idle speed for extendedperiods will be easier with the installation of a handthrottle. The engine should not be “raced” in order tospeed up the warm up process.

While the engine is idling, the application of a lightload (parasitic load) will assist in achieving theminimum operating temperature. The minimumoperating temperature is 82 °C (179.6 °F).

Recommendations for CoolantWarm UpWarm up an engine that has cooled below normaloperating temperatures due to inactivity. This shouldbe performed before the engine is returned to fulloperation. During operation in very cold temperatureconditions, damage to engine valve mechanisms canresult from engine operation for short intervals. Thiscan happen if the engine is started and the engine isstopped many times without being operated in orderto warm up completely.

When the engine is operated below normal operatingtemperatures, fuel and oil are not completely burnedin the combustion chamber. This fuel and oil causessoft carbon deposits to form on the valve stems.Generally, the deposits do not cause problems andthe deposits are burned off during operation atnormal engine operating temperatures.

When the engine is started and the engine is stoppedmany times without being operated in order to warmup completely, the carbon deposits become thicker.This can cause the following problems:

• Free operation of the valves is prevented.

• Valves become stuck.

• Pushrods may become bent.

• Other damage to valve train components canresult.

For this reason, when the engine is started,the engine must be operated until the coolanttemperature is 71 °C (160 °F) minimum. Carbondeposits on the valve stems will be kept at a minimumand the free operation of the valves and the valvecomponents will be maintained.

In addition, the engine must be thoroughly warmed inorder to keep other engine parts in better conditionand the service life of the engine will be generallyextended. Lubrication will be improved. There will beless acid and less sludge in the oil. This will providelonger service life for the engine bearings, the pistonrings, and other parts. However, limit unnecessaryidle time to ten minutes in order to reduce wear andunnecessary fuel consumption.

The Water Temperature Regulator andInsulated Heater Lines

The engine is equipped with a water temperatureregulator. When the engine coolant is below thecorrect operating temperature jacket water circulatesthrough the engine cylinder block and into theengine cylinder head. The coolant then returns to thecylinder block via an internal passage that bypassesthe valve of the coolant temperature regulator. Thisensures that coolant flows around the engine undercold operating conditions. The water temperatureregulator begins to open when the engine jacketwater has reached the correct minimum operatingtemperature. As the jacket water coolant temperaturerises above the minimum operating temperature thewater temperature regulator opens further allowingmore coolant through the radiator to dissipate excessheat.

The progressive opening of the water temperatureregulator operates the progressive closing of thebypass passage between the cylinder block andhead. This ensures maximum coolant flow tothe radiator in order to achieve maximum heatdissipation.

Note: Perkins discourages the use of all air flowrestriction devices such as radiator shutters.Restriction of the air flow can result in the following:high exhaust temperatures, power loss, excessivefan usage, and reduction in fuel economy.




A cab heater is beneficial in very cold weather. Thefeed from the engine and the return lines from thecab should be insulated in order to reduce heat lossto the outside air.

Insulating the Air Inlet and EngineCompartment

When temperatures below −18 °C (−0 °F) will befrequently encountered, an air cleaner inlet thatis located in the engine compartment may bespecified. An air cleaner that is located in the enginecompartment may also minimize the entry of snowinto the air cleaner. Also, heat that is rejected by theengine helps to warm the intake air.

Additional heat can be retained around the engine byinsulating the engine compartment.

i02322217

Fuel and the Effect from ColdWeather

Note: Only use grades of fuel that are recommendedby Perkins. Refer to this Operation and MaintenanceManual, “Fluid Recommendations”.

The following fuels can be used in this series ofengine.

• Group 1

• Group 2

• Group 3

• Special Fuels

Perkins prefer only Group 1 and Group 2 fuels foruse in this series of engines.

Group 1 fuels are the preferred Group of Fuels forgeneral use by Perkins. Group 1 fuels maximizeengine life and engine performance. Group 1 fuelsare usually less available than Group 2 fuels.Frequently, Group 1 fuels are not available in colderclimates during the winter.

Note: Group 2 fuels must have a maximum wearscar of 650 micrometers (HFRR to ISO 12156-1).

Group 2 fuels are considered acceptable for issuesof warranty. This group of fuels may reduce the lifeof the engine, the engine’s maximum power, and theengine’s fuel efficiency.

When Group 2 diesel fuels are used the followingcomponents provide a means of minimizing problemsin cold weather:

• Glow plugs (if equipped)

• Engine coolant heaters, which may be an OEMoption

• Fuel heaters, which may be an OEM option

• Fuel line insulation, which may be an OEM option

There are three major differences between Group1 fuels and Group 2 fuels. Group 1 fuels have thefollowing different characteristics to Group 2 fuels.

• A lower cloud point

• A lower pour point

• A higher energy per unit volume of fuel

Note: Group 3 fuels reduce the life of the engine. Theuse of Group 3 fuels is not covered by the Perkinswarranty.

Group 3 fuels include Low Temperature Fuels andAviation Kerosene Fuels.

Special fuels include Biofuel.

The cloud point is a temperature that allows waxcrystals to form in the fuel. These crystals can causethe fuel filters to plug.

The pour point is the temperature when diesel fuelwill thicken. The diesel fuel becomes more resistantto flow through fuel lines, fuel filters,and fuel pumps.

Be aware of these facts when diesel fuel ispurchased. Consider the average ambient airtemperature for the engine’s application. Enginesthat are fueled in one climate may not operate well ifthe engines are moved to another climate. Problemscan result due to changes in temperature.

Before troubleshooting for low power or for poorperformance in the winter, check the fuel for waxing.

Low temperature fuels may be available for engineoperation at temperatures below 0 °C (32 °F). Thesefuels limit the formation of wax in the fuel at lowtemperatures.

For more information on cold weather operation, referto the Operation and Maintenance Manual, “ColdWeather Operation and Fuel Related Components inCold Weather”.


38 SEBU8311-01Operation SectionCold Weather Operation

i01903588

Fuel Related Components inCold Weather

Fuel TanksCondensation can form in partially filled fuel tanks.Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for drainingwater and sediment from the bottom of the tanks.Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe.

Some fuel tanks use supply lines that take fueldirectly from the bottom of the tank. If the engine isequipped with this system, regular maintenance ofthe fuel system filter is important.

Drain the water and sediment from any fuel storagetank at the following intervals: weekly, oil changes,and refueling of the fuel tank. This will help preventwater and/or sediment from being pumped from thefuel storage tank and into the engine fuel tank.

Fuel FiltersIt is possible that a primary fuel filter is installedbetween the fuel tank and the engine fuel inlet. Afteryou change the fuel filter, always prime the fuelsystem in order to remove air bubbles from the fuelsystem. Refer to the Operation and MaintenanceManual in the Maintenance Section for moreinformation on priming the fuel system.

The micron rating and the location of a primary fuelfilter is important in cold weather operation. Theprimary fuel filter and the fuel supply line are the mostcommon components that are affected by cold fuel.

Fuel HeatersNote: The OEM may equip the application with fuelheaters. If this is the case, disconnect an electric typeof fuel heater in warm weather in order to preventoverheating of the fuel. If the type of fuel heater is aheat exchanger, the OEM should have included abypass for warm weather. Ensure that the bypass isoperational during warm weather in order to preventoverheating of the fuel.

For more information about fuel heaters (if equipped),refer to the OEM information.


SEBU8311-01 39Maintenance Section

Refill Capacities

Maintenance Section

Refill Capacitiesi02959059

Refill Capacities

Lubrication SystemThe refill capacities for the engine crankcasereflect the approximate capacity of the crankcaseor sump plus standard oil filters. Auxiliary oil filtersystems will require additional oil. Refer to the OEMspecifications for the capacity of the auxiliary oil filter.Refer to the Operation and Maintenance Manual,“Maintenance Section” for more information onLubricant Specifications.

402D-05 EngineTable 11

402D-05 EngineRefill Capacities

Compartment or System Minimum Maximum

Crankcase Oil Sump(1) 1.61 L(1.7 qt)

2.01 L(2.1 qt)

Total Lubrication System(2)

(1) These values are the approximate capacities for the crankcaseoil sump which includes the standard factory installed oil filters.Engines with auxiliary oil filters will require additional oil. Referto the OEM specifications for the capacity of the auxiliary oilfilter.

(2) The Total Lubrication System includes the capacity for theCrankcase Oil Sump plus the capacity of factory installed oilfilters and other filters added to the lubrication system. Enterthe value for the capacity of the Total Lubrication System inthis row.


403C-07 EngineRefill Capacities



3.05 L(3.2 qt)








4.4 L(4.6494qt)




403D-15 and 403D-15T EnginesTable 14

403D-15 and 403D-15T EnginesRefill Capacities



6 L(6.3 qt)





40 SEBU8311-01Maintenance SectionRefill Capacities





6 L(6.3 qt)








5.6 L(5.9175qt)




404D-22, 404D-22T and 404D-22TAEnginesTable 17

404D-22, 404D-22T and 404D-22TA EnginesRefill Capacities



10.6 L(11.2 qt)


(1) More than one style of sump may be used on these engines.Use these values to estimate the refill capacity. Use the engineoil level gauge to fill the engine to the correct oil level. Recordthe result in this table. These values are the approximatecapacities for the Crankcase Oil Sump which includes thestandard factory installed oil filters. Engines with auxiliary oilfilters will require additional oil. Refer to the OEM specificationsfor the capacity of the auxiliary oil filter.


Cooling SystemTo maintain the cooling system, the Total CoolingSystem capacity must be known. The approximatecapacity is for the engine cooling system. ExternalSystem capacities will vary among applications.Refer to the OEM specifications for the ExternalSystem capacity. This capacity information will beneeded in order to determine the amount of coolantthat is required for the Total Cooling System.



Compartment or System Liters Quarts

Engine Only 1.1 1.2

External System Per OEM(1)

Total Cooling System(2)

(1) The External System includes a radiator or an expansiontank with the following components: heat exchanger andpiping. Refer to the OEM specifications. Enter the value for thecapacity of the External System in this row.

(2) The Total Cooling System capacity includes the capacity ofthe Engine plus the External System. Enter the value for thecapacity of the Total Cooling System in this row.



Refill Capacities




Engine Only 1.2 1.3








Engine Only 1.9 2.0





403D-15 and 403D-15T EnginesTable 21

403D-15 and 403D-15TEnginesRefill Capacities


Engine Only 2.6 2.7








Engine Only 2.4 2.5





404D-22, 404D-22T and 404D-22TAEnginesTable 23

404D-22,404D-22T and 404D-22TA EnginesRefill Capacities


Engine Only 3.6 3.8




(2) The Total Cooling System capacity includes the capacity forthe Engine plus the External System. Enter the value for thecapacity of the Total Cooling System in this row.

i02959104

Fluid Recommendations

General Lubricant InformationBecause of government regulations regarding thecertification of exhaust emissions from the engine,the lubricant recommendations must be followed.

Engine Manufacturers Association (EMA)Oils

The “Engine Manufacturers AssociationRecommended Guideline on Diesel Engine Oil” isrecognized by Perkins. For detailed informationabout this guideline, see the latest edition of EMApublication, “EMA DHD -1”.



API Oils

The Engine Oil Licensing and Certification System bythe American Petroleum Institute (API) is recognizedby Perkins. For detailed information about thissystem, see the latest edition of the “API publicationNo. 1509”. Engine oils that bear the API symbol areauthorized by API.

g00546535Illustration 29Typical API symbol

Diesel engine oils CC, CD, CD-2, and CE havenot been API authorized classifications since 1January 1996. Table 24 summarizes the status ofthe classifications.

Table 24

API Classifications

Current Obsolete

CF-4, CG-4, CH-4 CE

CF CC, CD

CF-2(1) CD-2(1)

(1) The classifications CD-2 and American Petroleum InstituteCF-2 are for two-cycle diesel engines. Perkins does not sellengines that utilize CD-2 and API CF-2 oils.

Terminology

Certain abbreviations follow the nomenclature of“SAE J754”. Some classifications follow “SAE J183”abbreviations, and some classifications follow the“EMA Recommended Guideline on Diesel EngineOil”. In addition to Perkins definitions, there are otherdefinitions that will be of assistance in purchasinglubricants. Recommended oil viscosities can be foundin this publication, “Fluid Recommendations/EngineOil” topic (Maintenance Section).

Engine Oil

Commercial Oils

The performance of commercial diesel engineoils is based on American Petroleum Institute(API) classifications. These API classifications aredeveloped in order to provide commercial lubricantsfor a broad range of diesel engines that operate atvarious conditions.

Only use commercial oils that meet the followingclassifications:

• EMA DHD-1 multigrade oil (preferred oil)

• API CH-4 multigrade oil (preferred oil)

• ACEAE5

In order to make the correct choice of a commercialoil, refer to the following explanations:

EMA DHD-1 – The Engine ManufacturersAssociation (EMA) has developed lubricantrecommendations as an alternative to the API oilclassification system. DHD-1 is a RecommendedGuideline that defines a level of oil performance forthese types of diesel engines: high speed, four strokecycle, heavy-duty, and light duty. DHD-1 oils maybe used in Perkins engines when the following oilsare recommended: API CH-4, API CG-4, and APICF-4. DHD-1 oils are intended to provide superiorperformance in comparison to API CG-4 and APICF-4.

DHD-1 oils will meet the needs of high performancePerkins diesel engines that are operating in manyapplications. The tests and the test limits that areused to define DHD-1 are similar to the new APICH-4 classification. Therefore, these oils will alsomeet the requirements for diesel engines that requirelow emissions. DHD-1 oils are designed to control theharmful effects of soot with improved wear resistanceand improved resistance to plugging of the oil filter.These oils will also provide superior control of pistondeposits for engines with either two-piece steelpistons or aluminum pistons.

All DHD-1 oils must complete a full test programwith the base stock and with the viscosity grade ofthe finished commercial oil. The use of “API BaseOil Interchange Guidelines” are not appropriate forDHD-1 oils. This feature reduces the variation inperformance that can occur when base stocks arechanged in commercial oil formulations.



Refill Capacities

DHD-1 oils are recommended for use in extended oilchange interval programs that optimize the life of theoil. These oil change interval programs are basedon oil analysis. DHD-1 oils are recommended forconditions that demand a premium oil. Your Perkinsdealer or your Perkins distributor has the specificguidelines for optimizing oil change intervals.

API CH-4 – API CH-4 oils were developed in order tomeet the requirements of the new high performancediesel engines. Also, the oil was designed tomeet the requirements of the low emissions dieselengines. API CH-4 oils are also acceptable for usein older diesel engines and in diesel engines thatuse high sulfur diesel fuel. API CH-4 oils may beused in Perkins engines that use API CG-4 and APICF-4 oils. API CH-4 oils will generally exceed theperformance of API CG-4 oils in the following criteria:deposits on pistons, control of oil consumption, wearof piston rings, valve train wear, viscosity control,and corrosion.

Three new engine tests were developed for the APICH-4 oil. The first test specifically evaluates depositson pistons for engines with the two-piece steel piston.This test (piston deposit) also measures the controlof oil consumption. A second test is conductedwith moderate oil soot. The second test measuresthe following criteria: wear of piston rings, wear ofcylinder liners, and resistance to corrosion. A thirdnew test measures the following characteristics withhigh levels of soot in the oil: wear of the valve train,resistance of the oil in plugging the oil filter, andcontrol of sludge.

In addition to the new tests, API CH-4 oils havetougher limits for viscosity control in applications thatgenerate high soot. The oils also have improvedoxidation resistance. API CH-4 oils must pass anadditional test (piston deposit) for engines that usealuminum pistons (single piece). Oil performance isalso established for engines that operate in areaswith high sulfur diesel fuel.

All of these improvements allow the API CH-4oil to achieve optimum oil change intervals. APICH-4 oils are recommended for use in extended oilchange intervals. API CH-4 oils are recommendedfor conditions that demand a premium oil. YourPerkins dealer or your Perkins distributor has specificguidelines for optimizing oil change intervals.

Some commercial oils that meet the APIclassifications may require reduced oil changeintervals. To determine the oil change interval, closelymonitor the condition of the oil and perform a wearmetal analysis.

NOTICEFailure to follow these oil recommendations can causeshortened engine service life due to deposits and/orexcessive wear.

Total Base Number (TBN) and Fuel SulfurLevels for Diesel Engines

The Total Base Number (TBN) for an oil depends onthe fuel sulfur level. For engines that use distillatefuel, the minimum TBN of the new oil must be10 times the fuel sulfur level. The TBN is definedby “ASTM D2896”. The minimum TBN of the oilis 5 regardless of fuel sulfur level. Illustration 30demonstrates the TBN.


(Y) TBN by “ASTM D2896”(X) Percentage of fuel sulfur by weight(1) TBN of new oil(2) Change the oil when the TBN deteriorates to 50 percent of

the original TBN.

Use the following guidelines for fuel sulfur levels thatexceed 1.5 percent:

• Choose an oil with the highest TBN that meets oneof these classifications: EMA DHD-1 and API CH-4.

• Reduce the oil change interval. Base the oilchange interval on the oil analysis. Ensure that theoil analysis includes the condition of the oil and awear metal analysis.

Excessive piston deposits can be produced by an oilwith a high TBN. These deposits can lead to a lossof control of the oil consumption and to the polishingof the cylinder bore.

NOTICEOperating diesel engines with fuel sulphur levels over0.5 percent will require shortened oil change intervalsin order to help maintain adequate wear protection.



Table 25

Percentage of Sulfur inthe fuel

Oil change interval

Lower than 0.5 Normal

0.5 to 1.0 0.75 of normal

Greater than 1.0 0.50 of normal

Lubricant Viscosity Recommendations

The correct SAE viscosity grade of oil is determinedby the minimum ambient temperature duringcold engine start-up, and the maximum ambienttemperature during engine operation.

Refer to Table 26 (minimum temperature) in orderto determine the required oil viscosity for starting acold engine.

Refer to Table 26 (maximum temperature) in orderto select the oil viscosity for engine operation at thehighest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that isavailable to meet the requirement for the temperatureat start-up.

Table 26

Engine Oil Viscosity

Ambient TemperatureEMA LRG-1API CH-4

Viscosity Grade Minimum Maximum

SAE 0W20 −40 °C (−40 °F) 10 °C (50 °F)

SAE 0W30 −40 °C (−40 °F) 30 °C (86 °F)

SAE 0W40 −40 °C (−40 °F) 40 °C (104 °F)

SAE 5W30 −30 °C (−22 °F) 30 °C (86 °F)

SAE 5W40 −30 °C (−22 °F) 40 °C (104 °F)

SAE 10W30 −20 °C (−4 °F) 40 °C (104 °F)

SAE 15W40 −10 °C (14 °F) 50 °C (122 °F)

Synthetic Base Stock Oils

Synthetic base oils are acceptable for use inthese engines if these oils meet the performancerequirements that are specified for the engine.

Synthetic base oils generally perform better thanconventional oils in the following two areas:

• Synthetic base oils have improved flow at lowtemperatures especially in arctic conditions.

• Synthetic base oils have improved oxidationstability especially at high operating temperatures.

Some synthetic base oils have performancecharacteristics that enhance the service life of theoil. Perkins does not recommend the automaticextending of the oil change intervals for any type ofoil.

Re-refined Base Stock Oils

Re-refined base stock oils are acceptable foruse in Perkins engines if these oils meet theperformance requirements that are specified byPerkins. Re-refined base stock oils can be usedexclusively in finished oil or in a combination withnew base stock oils. The US military specificationsand the specifications of other heavy equipmentmanufacturers also allow the use of re-refined basestock oils that meet the same criteria.

The process that is used to make re-refined basestock oil should adequately remove all wear metalsthat are in the used oil and all the additives thatare in the used oil. The process that is used tomake re-refined base stock oil generally involves theprocess of vacuum distillation and hydrotreating theused oil. Filtering is adequate for the production ofhigh quality, re-refined base stock oil.

Lubricants for Cold Weather

When an engine is started and an engine is operatedin ambient temperatures below −20 °C (−4 °F), usemultigrade oils that are capable of flowing in lowtemperatures.

These oils have lubricant viscosity grades of SAE0W or SAE 5W.

When an engine is started and operated in ambienttemperatures below −30 °C (−22 °F), use a syntheticbase stock multigrade oil with an 0W viscosity gradeor with a 5W viscosity grade. Use an oil with a pourpoint that is lower than −50 °C (−58 °F).

The number of acceptable lubricants is limited incold weather conditions. Perkins recommends thefollowing lubricants for use in cold weather conditions:

First Choice – Use oil with an EMA DHD-1Recommended Guideline. Use a CH-4 oil that hasan API license. The oil should be either SAE 0W20,SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40lubricant viscosity grade.

Second Choice – Use an oil that has a CH-4additive package. Although the oil has not beentested for the requirements of the API license, the oilmust be either SAE 0W20, SAE 0W30, SAE 0W40,SAE 5W30, or SAE 5W40.



Refill Capacities

NOTICEShortened engine service life could result if secondchoice oils are used.

Aftermarket Oil Additives

Perkins does not recommend the use of aftermarketadditives in oil. It is not necessary to use aftermarketadditives in order to achieve the engine’s maximumservice life or rated performance. Fully formulated,finished oils consist of base oils and of commercialadditive packages. These additive packages areblended into the base oils at precise percentages inorder to help provide finished oils with performancecharacteristics that meet industry standards.

There are no industry standard tests that evaluatethe performance or the compatibility of aftermarketadditives in finished oil. Aftermarket additives maynot be compatible with the finished oil’s additivepackage, which could lower the performance of thefinished oil. The aftermarket additive could fail tomix with the finished oil. This could produce sludgein the crankcase. Perkins discourages the use ofaftermarket additives in finished oils.

To achieve the best performance from a Perkinsengine, conform to the following guidelines:

• Select the correct oil, or a commercial oil that meetsthe “EMA Recommended Guideline on DieselEngine Oil” or the recommended API classification.

• See the appropriate “Lubricant Viscosities” table inorder to find the correct oil viscosity grade for yourengine.

• At the specified interval, service the engine. Usenew oil and install a new oil filter.

• Perform maintenance at the intervals that arespecified in the Operation and MaintenanceManual, “Maintenance Interval Schedule”.

Oil analysis

Some engines may be equipped with an oil samplingvalve. If oil analysis is required the oil sampling valveis used to obtain samples of the engine oil. The oilanalysis will complement the preventive maintenanceprogram.

The oil analysis is a diagnostic tool that is used todetermine oil performance and component wearrates. Contamination can be identified and measuredthrough the use of the oil analysis. The oil analysisincludes the following tests:

• The Wear Rate Analysis monitors the wear of theengine’s metals. The amount of wear metal andtype of wear metal that is in the oil is analyzed. Theincrease in the rate of engine wear metal in theoil is as important as the quantity of engine wearmetal in the oil.

• Tests are conducted in order to detectcontamination of the oil by water, glycol or fuel.

• The Oil Condition Analysis determines the loss ofthe oil’s lubricating properties. An infrared analysisis used to compare the properties of new oil to theproperties of the used oil sample. This analysisallows technicians to determine the amount ofdeterioration of the oil during use. This analysisalso allows technicians to verify the performanceof the oil according to the specification during theentire oil change interval.

i02959102

Fluid Recommendations(Coolant Specifications)

General Coolant Information

NOTICENever add coolant to an overheated engine. Enginedamage could result. Allow the engine to cool first.

NOTICEIf the engine is to be stored in, or shipped to an areawith below freezing temperatures, the cooling systemmust be either protected to the lowest outside temper-ature or drained completely to prevent damage.

NOTICEFrequently check the specific gravity of the coolant forproper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

• Contamination of the cooling system

• Overheating of the engine

• Foaming of the coolant



NOTICENever operate an engine without water temperatureregulators in the cooling system. Water temperatureregulators help to maintain the engine coolant at theproper operating temperature. Cooling system prob-lems can develop without water temperature regula-tors.

Many engine failures are related to the coolingsystem. The following problems are related to coolingsystem failures: Overheating, leakage of the waterpump, and plugged radiators or heat exchangers.

These failures can be avoided with correct coolingsystem maintenance. Cooling system maintenance isas important as maintenance of the fuel system andthe lubrication system. Quality of the coolant is asimportant as the quality of the fuel and the lubricatingoil.

Coolant is normally composed of three elements:Water, additives, and glycol.

Water

Water is used in the cooling system in order totransfer heat.

Distilled water or deionized water isrecommended for use in engine cooling systems.

DO NOT use the following types of water in coolingsystems: Hard water, softened water that has beenconditioned with salt, and sea water.

If distilled water or deionized water is not available,use water with the properties that are listed in Table27.

Table 27

Acceptable Water

Property Maximum Limit

Chloride (Cl) 40 mg/L

Sulfate (SO4) 100 mg/L

Total Hardness 170 mg/L

Total Solids 340 mg/L

Acidity pH of 5.5 to 9.0

For a water analysis, consult one of the followingsources:

• Local water utility company

• Agricultural agent

• Independent laboratory

Additives

Additives help to protect the metal surfaces ofthe cooling system. A lack of coolant additives orinsufficient amounts of additives enable the followingconditions to occur:

• Corrosion

• Formation of mineral deposits

• Rust

• Scale

• Foaming of the coolant

Many additives are depleted during engine operation.These additives must be replaced periodically.

Additives must be added at the correct concentration.Overconcentration of additives can cause theinhibitors to drop out-of-solution. The deposits canenable the following problems to occur:

• Formation of gel compounds

• Reduction of heat transfer

• Leakage of the water pump seal

• Plugging of radiators, coolers, and small passages

Glycol

Glycol in the coolant helps to provide protectionagainst the following conditions:

• Boiling

• Freezing

• Cavitation of the water pump

For optimum performance, Perkins recommends a1:1 mixture of a water/glycol solution.

Note: Use a mixture that will provide protectionagainst the lowest ambient temperature.

Note: 100 percent pure glycol will freeze at atemperature of −23 °C (−9 °F).

Most conventional antifreezes use ethylene glycol.Propylene glycol may also be used. In a 1:1 mixturewith water, ethylene and propylene glycol providesimilar protection against freezing and boiling. SeeTables 28 and 29.



Refill Capacities

Table 28

Ethylene Glycol

Concentration Freeze Protection

50 Percent −36 °C (−33 °F)

60 Percent −51 °C (−60 °F)

NOTICEDo not use propylene glycol in concentrations that ex-ceed 50 percent glycol because of propylene glycol’sreduced heat transfer capability. Use ethylene glycolin conditions that require additional protection againstboiling or freezing.

Table 29

Propylene Glycol

Concentration Freeze Protection

50 Percent −29 °C (−20 °F)

To check the concentration of glycol in the coolant,measure the specific gravity of the coolant.

Coolant Recommendations

• ELC____________________________Extended Life Coolant

• SCA___________________Supplement Coolant Additive

• ASTM__________________________________________AmericanSociety for Testing and Materials

The following two coolants are used in Perkins dieselengines:

Preferred – Perkins ELC

Acceptable – A commercial heavy-duty antifreezethat meets “ASTM D4985” specifications

NOTICEDo not use a commercial coolant/antifreeze that on-ly meets the ASTM D3306 specification. This type ofcoolant/antifreeze is made for light automotive appli-cations.

Perkins recommends a 1:1 mixture of water andglycol. This mixture of water and glycol will provideoptimum heavy-duty performance as a antifreeze.This ratio may be increased to 1:2 water to glycol ifextra freezing protection is required.

Note: A commercial heavy-duty antifreeze thatmeets “ASTM D4985” specifications MAY require atreatment with an SCA at the initial fill. Read the labelor the instructions that are provided by the OEM ofthe product.

In stationary engine applications and marine engineapplications that do not require anti-boil protectionor freeze protection, a mixture of SCA and wateris acceptable. Perkins recommends a six percentto eight percent concentration of SCA in thosecooling systems. Distilled water or deionized wateris preferred. Water which has the recommendedproperties may be used.

Table 30

Coolant Service Life

Coolant Type Service Life

Perkins ELC 6,000 Service Hours orThree Years

Commercial Heavy-DutyAntifreeze that meets“ASTM D4985”

3000 Service Hours orTwo Years

Perkins POWERPARTSCA


Commercial SCA andWater


ELC

Perkins provides ELC for use in the followingapplications:

• Heavy-duty spark ignited gas engines

• Heavy-duty diesel engines

• Automotive applications

The anti-corrosion package for ELC is different fromthe anti-corrosion package for other coolants. ELCis an ethylene glycol base coolant. However, ELCcontains organic corrosion inhibitors and antifoamagents with low amounts of nitrite. Perkins ELChas been formulated with the correct amount ofthese additives in order to provide superior corrosionprotection for all metals in engine cooling systems.

ELC is available in a 1:1 premixed cooling solutionwith distilled water. The Premixed ELC providesfreeze protection to −36 °C (−33 °F). The PremixedELC is recommended for the initial fill of the coolingsystem. The Premixed ELC is also recommended fortopping off the cooling system.

Containers of several sizes are available. Consultyour Perkins distributor for the part numbers.



ELC Cooling System Maintenance

Correct additions to the Extended LifeCoolant

NOTICEUse only Perkins products for pre-mixed or concen-trated coolants.

Mixing Extended Life Coolant with other products re-duces the Extended Life Coolant service life. Failure tofollow the recommendations can reduce cooling sys-tem components life unless appropriate corrective ac-tion is performed.

In order to maintain the correct balance betweenthe antifreeze and the additives, you must maintainthe recommended concentration of ELC. Loweringthe proportion of antifreeze lowers the proportion ofadditive. This will lower the ability of the coolant toprotect the system from pitting, from cavitation, fromerosion, and from deposits.

NOTICEDo not use a conventional coolant to top-off a coolingsystem that is filled with Extended Life Coolant (ELC).

Do not use standard supplemental coolant additive(SCA).

When using Perkins ELC, do not use standard SCA’sor SCA filters.

ELC Cooling System Cleaning

Note: If the cooling system is already using ELC,cleaning agents are not required to be used atthe specified coolant change interval. Cleaningagents are only required if the system has beencontaminated by the addition of some other type ofcoolant or by cooling system damage.

Clean water is the only cleaning agent that is requiredwhen ELC is drained from the cooling system.

Before the cooling system is filled, the heater control(if equipped) must be set to the hot position. Referto the OEM in order to set the heater control. Afterthe cooling system is drained and the cooling systemis refilled, operate the engine until the coolant levelreaches the normal operating temperature anduntil the coolant level stabilizes. As needed, addthe coolant mixture in order to fill the system to thespecified level.

Changing to Perkins ELC

To change from heavy-duty antifreeze to the PerkinsELC, perform the following steps:

NOTICECare must be taken to ensure that all fluids arecontained during performance of inspection, main-tenance, testing, adjusting and the repair of theproduct. Be prepared to collect the fluid with suitablecontainers before opening any compartment or dis-assembling any component containing fluids.

Dispose of all fluids according to local regulations andmandates.

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to localregulations.

3. Flush the system with clean water in order toremove any debris.

4. Use Perkins cleaner to clean the system. Followthe instruction on the label.

5. Drain the cleaner into a suitable container. Flushthe cooling system with clean water.

6. Fill the cooling system with clean water andoperate the engine until the engine is warmed to49° to 66°C (120° to 150°F).

NOTICEIncorrect or incomplete flushing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sure tocompletely flush the cooling system with clear water.Continue to flush the system until all the signs of thecleaning agent are gone.

7. Drain the cooling system into a suitable containerand flush the cooling system with clean water.

Note: The cooling system cleaner must be thoroughlyflushed from the cooling system. Cooling systemcleaner that is left in the system will contaminate thecoolant. The cleaner may also corrode the coolingsystem.

8. Repeat Steps 6 and 7 until the system iscompletely clean.

9. Fill the cooling system with the Perkins PremixedELC.



Refill Capacities

ELC Cooling System Contamination

NOTICEMixing ELC with other products reduces the effective-ness of the ELC and shortens the ELC service life.Use only Perkins Products for premixed or concen-trate coolants. Failure to follow these recommenda-tions can result in shortened cooling system compo-nent life.

ELC cooling systems can withstand contamination toa maximum of ten percent of conventional heavy-dutyantifreeze or SCA. If the contamination exceeds tenpercent of the total system capacity, perform ONE ofthe following procedures:

• Drain the cooling system into a suitable container.Dispose of the coolant according to localregulations. Flush the system with clean water. Fillthe system with the Perkins ELC.

• Drain a portion of the cooling system into a suitablecontainer according to local regulations. Then, fillthe cooling system with premixed ELC. This shouldlower the contamination to less than 10 percent.

• Maintain the system as a conventional Heavy-DutyCoolant. Treat the system with an SCA. Changethe coolant at the interval that is recommended forthe conventional Heavy-Duty Coolant.

Commercial Heavy-Duty Antifreeze andSCA

NOTICECommercial Heavy-Duty Coolant which containsAmine as part of the corrision protection system mustnot be used.

NOTICENever operate an engine without water temperatureregulators in the cooling system. Water temperatureregulators help to maintain the engine coolant at thecorrect operating temperature. Cooling system prob-lems can develop without water temperature regula-tors.

Check the antifreeze (glycol concentration) inorder to ensure adequate protection against boilingor freezing. Perkins recommends the use of arefractometer for checking the glycol concentration.

Perkins engine cooling systems should be tested at500 hour intervals for the concentration of SCA.

Additions of SCA are based on the results of the test.An SCA that is liquid may be needed at 500 hourintervals.

Refer to Table 31 for part numbers and for quantitiesof SCA.

Table 31

Perkins Liquid SCA

Part Number Quantity

21825735 10

Adding the SCA to Heavy-Duty Coolantat the Initial Fill

Commercial heavy-duty antifreeze that meets “ASTMD4985” specifications MAY require an addition ofSCA at the initial fill. Read the label or the instructionsthat are provided by the OEM of the product.

Use the equation that is in Table 32 to determine theamount of Perkins SCA that is required when thecooling system is initially filled.

Table 32

Equation For Adding The SCA To The Heavy-DutyCoolant At The Initial Fill

V × 0.045 = X

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Table 33 is an example for using the equation thatis in Table 32.

Table 33

Example Of The Equation For Adding The SCA ToThe Heavy-Duty Coolant At The Initial Fill

Total Volumeof the CoolingSystem (V)

MultiplicationFactor

Amount ofSCA that isRequired (X)

15 L (4 US gal) × 0.045 0.7 L (24 oz)

Adding The SCA to The Heavy-DutyCoolant For Maintenance

Heavy-duty antifreeze of all types REQUIRE periodicadditions of an SCA.

Test the antifreeze periodically for the concentrationof SCA. For the interval, refer to the Operationand Maintenance Manual, “Maintenance IntervalSchedule” (Maintenance Section). Test theconcentration of SCA.

Additions of SCA are based on the results of thetest. The size of the cooling system determines theamount of SCA that is needed.



Use the equation that is in Table 34 to determine theamount of Perkins SCA that is required, if necessary:

Table 34

Equation For Adding The SCA To The Heavy-DutyCoolant For Maintenance

V × 0.014 = X

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Table 35 is an example for using the equation thatis in Table 34.

Table 35

Example Of The Equation For Adding The SCA ToThe Heavy-Duty Coolant For Maintenance

Total Volumeof the CoolingSystem (V)

MultiplicationFactor

Amount ofSCA that isRequired (X)

15 L (4 US gal) × 0.014 0.2 L (7 oz)

Cleaning the System of Heavy-DutyAntifreeze

Perkins cooling system cleaners are designedto clean the cooling system of harmful scaleand corrosion. Perkins cooling system cleanersdissolve mineral scale, corrosion products, light oilcontamination and sludge.

• Clean the cooling system after used coolant isdrained or before the cooling system is filled withnew coolant.

• Clean the cooling system whenever the coolant iscontaminated or whenever the coolant is foaming.

i02959101

Fluid Recommendations(Fuel Specification)

• Glossary

• ISO International Standards Organization

• ASTM American Society for Testing and Materials

• HFRR High Frequency Reciprocating Rig forLubricity testing of diesel fuels

• FAME Fatty Acid Methyl Esters

• CFR Co-ordinating Fuel Research

• LSD Low Sulfur Diesel

• ULSD Ultra Low Sulfur Diesel

• RME Rape Methyl Ester

• SME Soy Methyl Ester

• EPA Environmental Protection Agency of theUnited States

General Information

NOTICEEvery attempt is made to provide accurate, up to dateinformation. By use of this document you agree thatPerkins Engines Company Limited is not responsiblefor errors or omissions.

NOTICEThese recommendations are subject to change with-out notice. Contact your local Perkins distributor forthe most up to date recommendations.

Diesel Fuel RequirementsSatisfactory engine performance is dependent on theuse of a good quality fuel. The use of a good qualityfuel will give the following results: long engine life andacceptable exhaust emissions levels. The fuel mustmeet the minimum requirements that are stated intables 36, 37 and 38.

NOTICEThe footnotes are a key part of the Perkins Specifica-tion for Distillate Diesel Fuel Table. Read ALL of thefootnotes.



Refill Capacities

Table 36

Perkins Specification for Distillate Diesel Fuel (1)

Property UNITS Requirements “ASTM”Test “ISO”Test

Aromatics %Volume 35% maximum D1319 “ISO”3837

Ash %Weight 0.02% maximum D482 “ISO”6245

Carbon Residue on10% Bottoms

%Weight 0.35% maximum D524 “ISO”4262

Cetane Number (2) - 40 minimum D613/D6890 “ISO”5165

Cloud Point °C The cloud point mustnot exceed the lowestexpected ambienttemperature.

D2500 “ISO”3015

Copper StripCorrosion

- No. 3 maximum D130 “ISO”2160

Density at 15 °C(59 °F) (3)

Kg / M 3 801 minimum and 876maximum

No equivalent test “ISO 3675 ”“ISO 12185”

Distillation °C 10% at 282 °C(539.6 °F) maximum90% at 360 °C (680 °F)maximum

D86 “ISO”3405

Flash Point °C legal limit D93 “ISO”2719

Thermal Stability - Minimum of 80%reflectance after agingfor 180 minutes at150 °C (302 °F)

D6468 No equivalent test

Pour Point °C 6 °C (42.8 °F) minimumbelow ambienttemperature

D97 “ISO”3016

Sulfur (1)(4) %mass The level of sulfurthat is in the fuel iscontrolled by emissionsregulations. Refer toTables 37 and 38 formore information.

D5453/D26222 “ISO 20846 ”“ISO 20884”

Kinematic Viscosity (5) “MM”2“/S (cSt)” The viscosity of thefuel that is delivered tothe fuel injection pump.“1.4 minimum/4.5maximum”

D445 “ISO”3405

Water and sediment % weight 0.1% maximum D1796 “ISO”3734

Water % weight 0.1% maximum D1744 No equivalent test

Sediment % weight 0.05% maximum D473 “ISO”3735(continued)



(Table 36, contd)

Gums and Resins (6) mg/100mL 10 mg per 100 mLmaximum

D381 “ISO”6246

Lubricity correctedwear scar diameter at60 °C (140 °F). (7)

mm 0.46 maximum D6079 “ISO”12156-1

(1) This specification includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to“ASTM D5453”, “ASTM D2622”, or “ISO 20846, ISO 20884” test methods. This specification includes the requirements for Low Sulfur Diesel(LSD). LSD fuel will have ≤500 ppm (0.05%) sulfur. Refer to following:“ASTM 5453, ASTM D2622”, “ISO 20846”, and “ISO 20884 testmethods”. Refer to Tables 37 and 38.

(2) A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather.(3) “Via standards tables, the equivalent API gravity for the minimum density of 801 kg / m3 (kilograms per cubic meter) is 45 and for themaximum density of 876 kg / m3 is 30”.

(4) Regional regulations, national regulations or international regulations can require a fuel with a specific sulfur limit. Consult all applicableregulations before selecting a fuel for a given engine application. Perkins fuel systems and engine components can operate on high sulfurfuels in territories that are non-emissions regulated. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potentialfor corrosion of internal components. Fuel sulfur levels above 0.5% may significantly shorten the oil change interval. For additionalinformation, refer to this manual, “Fluid recommendations (General lubricant Information)”.

(5) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimumviscosity requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the “ASTM D445” testmethod or the “ISO 3104” test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain 1.4 cSt orgreater viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to 4.5cSt at the fuel injection pump.

(6) Follow the test conditions and procedures for gasoline (motor).(7) The lubricity of a fuel is a concern with low sulfur and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1or ASTM D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements,consult your fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additivescan cause problems in the fuel system.

NOTICEOperating with fuels that do not meet the Perkins rec-ommendations can cause the following effects: Start-ing difficulty, poor combustion, deposits in the fuel in-jectors, reduced service life of the fuel system, de-posits in the combustion chamber, and reduced ser-vice life of the engine.

Diesel Fuel CharacteristicsPerkins Recommendation

Cetane Number

Fuel that has a high cetane number will give a shorterignition delay. This will produce a better ignitionquality. Cetane numbers are derived for fuels againstproportions of cetane and heptamethylnonane in thestandard CFR engine. Refer to “ISO 5165” for thetest method.

Cetane numbers in excess of 45 are normallyexpected from current diesel fuel. However, a cetanenumber of 40 may be experienced in some territories.The United States of America is one of the territoriesthat can have a low cetane value. A minimum cetanevalue of 40 is required during average startingconditions. A higher cetane value may be requiredfor operations at high altitudes or in cold weatheroperations.

Fuel with a low cetane number can be the root causeof problems during cold start.

Viscosity

Viscosity is the property of a liquid of offeringresistance to shear or flow. Viscosity decreases withincreasing temperature. This decrease in viscosityfollows a logarithmic relationship for normal fossilfuel. The common reference is to kinematic viscosity.This is the quotient of the dynamic viscosity that isdivided by the density. The determination of kinematicviscosity is normally by readings from gravity flowviscometers at standard temperatures. Refer to “ISO3104” for the test method.

The viscosity of the fuel is significant because fuelserves as a lubricant for the fuel system components.Fuel must have sufficient viscosity in order to lubricatethe fuel system in both extremely cold temperaturesand extremely hot temperatures. If the kinematicviscosity of the fuel is lower than 1.4 cSt at the fuelinjection pump damage to the fuel injection pumpcan occur. This damage can be excessive scuffingand seizure. Low viscosity may lead to difficult hotrestarting, stalling and loss of performance. Highviscosity may result in seizure of the pump.

Perkins recommends kinematic viscosities of 1.4 and4.5 mm2/sec that is delivered to the fuel injectionpump.



Refill Capacities

Density

Density is the mass of the fuel per unit volumeat a specific temperature. This parameter has adirect influence on engine performance and a directinfluence on emissions. This determines the heatoutput from a given injected volume of fuel. Thisis generally quoted in the following kg/m at 15 °C(59 °F).

Perkins recommends a value of density of 841 kg/min order to obtain the correct power output. Lighterfuels are acceptable but these fuels will not producethe rated power.

Sulfur

The level of sulfur is governed by emissionslegislations. Regional regulation, national regulationsor international regulations can require a fuel witha specific sulfur limit. The sulfur content of the fueland the fuel quality must comply with all existing localregulations for emissions.

Tables 37 and 38 list the guidelines for the correctsulfur level for specific territories. Consult allapplicable regulations before selecting the fuel for agiven engine application.

Table 37

Territory Fuel Requirements from 2007

EPA Low Sulfur (500 ppm) maximum

Sulfur/Power

Low sulfur(300 ppm)maximumfor less thanor equal to19 kW

Sulphur(1000 ppm)maximumfor greaterthan 19 kW

ECModels 402D-

05 and403D-07

403D-11,403D-15,403D-15T,403D-17,404D-15.404D-22,404D-22T and404D-22TA

Non-RegulatedTerritories

Sulfur limit of less than 4000 ppm

Table 38

Territory Fuel Requirements from 2010

EPA Ultra Low Sulfur (15 ppm) maximum

Sulfur/Power

Ultra Lowsulphur(10 ppm)maximumfor less thanor equal to37 kW

Low sulphur(300 ppm)maximumfor greaterthan 37 kW

ECModels 402D-05,

403D-07,403D-11,403D-15,403D-15T,403D-17,404D-15

404D-22,404D-22T and404D-22TA

NonRegulatedTerritories

Sulfur limit of less than 4000 ppm

By using the test methods “ASTM D5453, ASTMD2622, or ISO 20846 ISO 20884”, the content ofsulfur in low sulfur diesel (LSD) fuel must be below500 PPM 0.05%. By using the test methods “ASTMD5453, ASTM D2622, or ISO 20846 ISO 20884”,the content of sulfur in ultra low sulfur (ULSD) fuelmust be below 15 PPM 0.0015%. The lubricity ofthese fuels must not exceed wear scar diameter of0.46 mm (0.0181 inch). The fuel lubricity test must beperformed on a HFRR, operated at 60 °C (140 °F).Refer to “ISO 12156-1 ”.

In some parts of the world and for some applications,high sulfur fuels above 0.5% by mass might onlybe available. Fuel with very high sulfur contentcan cause engine wear. High sulfur fuel will havea negative impact on emissions of particulates.High sulfur fuel can be used provided that the localemissions legislation will allow the use. High sulfurfuel can be used in countries that do not regulateemissions.

When only high sulfur fuels are available, it willbe necessary that high alkaline lubricating oil isused in the engine or that the lubricating oil changeinterval is reduced. Refer to this Operation andMaintenance Manual, “Fliud Recommendations(Genernal Lubrication Information)” for informationon sulfur in fuel.



Lubricity

This is the capability of the fuel to prevent pumpwear. The fluid’s lubricity describes the ability of thefluid to reduce the friction between surfaces that areunder load. This ability reduces the damage that iscaused by friction. Fuel injection systems rely on thelubricating properties of the fuel. Until fuel sulfur limitswere mandated, the fuel’s lubricity was generallybelieved to be a function of fuel viscosity.

The lubricity has particular significance to the currentlow viscosity fuel, low sulfur fuel and low aromaticfossil fuel. These fuels are made in order to meetstringent exhaust emissions. A test method formeasuring the lubricity of diesel fuels has beendeveloped and the test is based on the HFRRmethod that is operated at 60 °C (140 °F). Refer to“ISO 12156 part 1 and CEC document F06-A-96” forthe test method.

Lubricity wear scar diameter of 0.46 mm (0.0181 inch)MUST NOT be exceeded. The fuel lubricity test mustbe performed on a HFRR, operated at 60 °C (140 °F).Refer to “ISO 12156-1 ”.

Fuel additives can enhance the lubricity of a fuel.Contact your fuel supplier for those circumstanceswhen fuel additives are required. Your fuel suppliercan make recommendations for additives to useand for the proper level of treatment. Refer to “FuelAdditive” for more information.

Distillation

This is an indication of the mixture of differenthydrocarbons in the fuel. A high ratio of light weighthydrocarbons can affect the characteristics ofcombustion.

Classification of the Fuels

Diesel engines have the ability to burn a wide varietyof fuels. These fuels are divided into four generalgroups: Ref to table 39

Table 39

Fuel Groups Classification

Group 1 Preferred fuels Full life of theProduct

Group 2 Permissible fuels These fuelsMAY causereducedengine life andperformance

Group 3 Aviation fuels These fuelsWILL causereducedengine life andperformance

Group 4 Biodiesel

Group 1 Specifications (Preferred Fuels)

This group of fuel specifications is consideredacceptable:

• EN590 DERV Grade A, B, C, E, F, Class, 0, 1, 2,3, and 4

• “ASTM D975”, Grade 2D S15, and Grade 2D S500

• “JIS K2204 Grades 1,2,3 and Special Grade 3”This grade of fuel must meet the minimum lubricityrequirements that are stated in table 36.

• “BS2869 Class A2” Off-Highway Gas Oil RedDiesel

Note: BS2869 can only be used if the sulfur levelmeets the specifications that are listed in tables 37and 38. An analysis of a sample of fuel must beconducted in order to check the sulfur level.

Note: The use of LSD fuel and the use of ULSDfuel is acceptable provided that the fuels meet theminimum requirements that are stated in tables 36,37 and 38. The lubricity of these fuels must notexceed wear scar diameter of 0.46 mm (0.0181 inch).The lubricity test must be performed on a HFRR,operated at 60 °C (140 °F). Refer to “ISO 12156-1”. By using the test methods “ASTM D5453, ASTMD2622, or ISO 20846 ISO 20884”, the content ofsulfur in LSD fuel must be below 500 PPM 0.05%. Byusing the test methods “ASTM D5453, ASTM D2622,or ISO 20846 ISO 20884”, the content of sulfur inULSD fuel must be below 15 PPM 0.0015%.

Group 2 Specifications (PermissibleFuels)

This group of fuel specifications is consideredacceptable, but these fuels MAY reduce the enginelife and performance.



Refill Capacities

• “ASTM D975”, Grade 1D S15, and Grade 1D S500

• “JP7 (MIL-T-38219)”

• “NATO F63”

Note: JP7 and NATO F63 can only be used if thesulfur level meets the specifications that are listedin tables 37 and 38. An analysis of a sample of fuelmust be conducted in order to check the sulfur level.

Group 3 Specifications (Aviation Fuels)

This group of fuel specification must be used onlywith the appropriate fuel additive. This fuel WILLreduce engine life and performance.

• “NATO F34 (MIL-DTL-83133E)”

• “NATO F35 (MIL-DTL-83133E)”

• “NATO JP8 (MIL-DTL-83133E)”

• “NATO F-44 (MIL-DTL-5624U)”

• “NATO JP5 (MIL-DTL-5624U)”

• “Jet A (ASTM D1655)”

• “Jet A1 (ASTM D1655)”

Note: All the above fuels can ONLY be used if thesulfur level meets the specifications that are listedin tables 37 and 38. An analysis of a sample of fuelmust be conducted in order to check the sulfur level.

Note: These fuels are only acceptable providedthat these fuels are used with an appropriate fueladditive. These fuels must meet the requirementsthat are stated in tables 36, 37 and 38. Fuel samplesshould be analyzed for the compliance. These fuelsMUST NOT exceed lubricity wear scar diameter of0.46 mm (0.0181 inch). The fuel lubricity test must beperformed on a HFRR, operated at 60 °C (140 °F).Refer to “ISO 12156-1 ”. Fuels must have minimumviscosity of 1.4 centistokes that is delivered to the fuelinjection pump. Fuel cooling may be required in orderto maintain minimum viscosity of 1.4 centistokes thatis delivered to the fuel injection pump.

Group 4 Biodiesel

Biodiesel is a fuel that can be defined as mono-alkylesters of fatty acids. Biodiesel is a fuel that canbe made from a variety of feedstock. The mostcommonly available biodiesel in europe is RapeMethyl Ester (REM). This biodiesel is derived fromrapeseed oil. Soy Methyl Ester (SME) is the mostcommon biodiesel in the United States. This biodieselis derived from soybean oil. Soybean oil or rapeseedoil are the primary feedstocks. These fuels aretogether known as Fatty Acid Methyl Esters (FAME).

Raw pressed vegetable oils are NOT acceptable foruse as a fuel in any concentration in compressionengines. Without esterification, these oils gel in thecrankcase and the fuel tank. These fuels may not becompatible with many of the elastomers that are usedin engines that are manufactured today. In originalforms, these oils are not suitable for use as a fuelin compression engines. Alternate base stocks forbiodiesel may include animal tallow, waste cookingoils, or a variety of other feedstocks. In order to useany of the products that are listed as fuel, the oilmust be esterified.

Note: Engines that are manufactured by Perkinsare certified by use of the prescribed EnvironmentalProtection Agency (EPA) and European Certificationfuels. Perkins does not certify engines on any otherfuel. The user of the engine has the responsibilityof using the correct fuel that is recommended bythe manufacturer and allowed by the EPA and otherappropriate regulatory agencies.

Recommendation for the use of biodiesel

The neat biodiesel must conform to “EN14214”or “ASTM D675” regulations. A maximum of 10%mixture of biodiesel can be used in mineral diesel fuel.The mineral diesel fuel must conform to “EN590”,“ASTM D975” or “BS2869 Grade A2” regulations.

In North America, biodiesel and mixtures of biodieselmust be purchased from the BQ9000 authorizedmanufacturers and BQ9000 certified distributors.

In other areas of the world, the use of biodiesel that isauthorized and certified by an appropriate biodieselquality body is required.

Note: When biodiesel, or any blend of biodiesel isused, the user has the responsibility for obtaining theproper local exemptions, regional exemptions, and/ornational exemptions that are required for the useof biodiesel in any Perkins engine that is regulatedby emissions standards. Biodiesel that meets“EN14214” is acceptable. The biodiesel must beblended with an acceptable distillate diesel fuel at themaximum stated percentages. However, the followingoperational recommendations must be followed:



• The oil change interval can be affected by the useof biodiesel. Use Services Oil Analysis in orderto monitor the condition of the engine oil. UseServices Oil Analysis also in order to determine theoil change interval that is optimum.

• Confirm that biodiesel is acceptable for use withthe manufacturer of the fuel filters.

• In a comparison of distillate fuels to biodiesel,biodiesel provides less energy per gallon by 5% to7%. Do NOT change the engine rating in order tocompensate for the power loss. This will help avoidengine problems when the engine is convertedback to 100 percent distillate diesel fuel.

• The compatibility of the elastomers with biodieselis being monitored. The condition of seals andhoses should be monitored regularly.

• Biodiesel may pose low ambient temperatureproblems for both storage and operation. At lowambient temperatures, fuel may need to be storedin a heated building or a heated storage tank. Thefuel system may require heated fuel lines, filters,and tanks. Filters may plug and fuel in the tank maysolidify at low ambient temperatures if precautionsare not taken. Consult your biodiesel supplier forassistance in the blending and attainment of theproper cloud point for the fuel.

• Biodiesel has poor oxidation stability, whichcan result in long term problems in the storageof biodiesel. The poor oxidation stability mayaccelerate fuel oxidation in the fuel system.This is especially true in engines with electronicfuel systems because these engines operate athigher temperatures. Consult the fuel supplier foroxidation stability additives.

• Biodiesel is a fuel that can be made from a varietyof feedstock. The feedstock that is used canaffect the performance of the product. Two of thecharacteristics of the fuel that are affected arecold flow and oxidation stability. Contact your fuelsupplier for guidance.

• Biodiesel or biodiesel blends are not recommendedfor engines that will operate occasionally. Thisis due to poor oxidation stability. If the user isprepared to accept some risk, then limit biodieselto a maximum of B5. Examples of applications thatshould limit the use of biodiesel are the following:Standby Generator sets and certain emergencyvehicles

• Biodiesel is an excellent medium for microbialcontamination and growth. Microbial contaminationand growth can cause corrosion in the fuel systemand premature plugging of the fuel filter. Theuse of conventionalanti-microbial additives andthe effectiveness of conventional anti-microbialadditives in biodiesel is not known. Consult yoursupplier of fuel and additive for assistance.

• Care must be taken in order to remove waterfrom fuel tanks. Water accelerates microbialcontamination and growth. When biodiesel iscompared to distillate fuels, water is naturally morelikely to exist in the biodiesel.

Fuel for Cold Weather Operation

The European standard “EN590” contains climatedependant requirements and a range of options. Theoptions can be applied differently in each country.There are 5 classes that are given to arctic climatesand severe winter climates. 0, 1, 2, 3, and 4.

Fuel that complies with “EN590” CLASS 4 can beused at temperatures as low as −44 °C (−47.2 °F).Refer to “EN590” for a detailed discretion of thephysical properties of the fuel.

The diesel fuel “ASTM D975 Grade 1-D S15 or S500”that is used in the united states of america may beused in very cold temperatures that are below −18 °C(−0.4 °F).

In extreme cold ambient conditions, you may alsouse fuels that are listed in the table 40. These fuelsare intended to be used in temperatures that can beas low as −54 °C (−65.2 °F).

Table 40

Light Distillate Fuels (1)

Specification Grade

“MIL-DTL-5624U” JP-5

“MIL-DTL-83133E” JP-8

“ASTM D1655” Jet-A-1(1) The use of these fuels is acceptable with an appropriate fueladditive and the fuels must meet minimum requirements thatare stated in Tables 36, 37 and 38 . Fuel samples should beanalyzed for the compliance. Fuels MUST NOT exceed 0.46mm lubricity wear scar diameter that is tested on a HFFR .The test must be performed at 60 °C. Refer to “ISO 12156-1”.Fuels must have minimum viscosity of 1.4 centistokes thatis delivered to the fuel injection pump. Fuel cooling maybe required in order to maintain minimum viscosity of 1.4centistokes that is delivered to the fuel injection pump.



Refill Capacities

Mixing alcohol or gasolinewith diesel fuel can pro-duce an explosivemixture in the engine crankcaseor the fuel tank. Alcohol or gasoline must not beused in order to dilute diesel fuel. Failure to followthis instruction may result in death or personal in-jury.

There are many other diesel fuel specifications thatare published by governments and by technologicalsocieties. Usually, those specifications do not reviewall the requirements that are addressed in tables 36,37 and 38. To ensure optimum engine performance,a complete fuel analysis should be obtained beforeengine operation. The fuel analysis should includeall of the properties that are stated in the tables 36,37 and 38.

Fuel Additive

Supplemental diesel fuel additives are not generallyrecommended. This is due to potential damage tothe fuel system or the engine. Your fuel supplieror the fuel manufacturer will add the appropriatesupplemental diesel fuel additives.

Perkins recognizes the fact that additives maybe required in some special circumstances. Fueladditives need to be used with caution. The additivemay not be compatible with the fuel. Some additivesmay precipitate. This action causes deposits in thefuel system. The deposits may cause seizure. Someadditives may be corrosive, and some additives maybe harmful to the elastomers in the fuel system.Some additives may raise fuel sulfur levels abovethe maximum that is allowed by the EPA or theother regulatory agencies. Contact your fuel supplierfor those circumstances when fuel additives arerequired. Your fuel supplier can recommend theappropriate fuel additive and the correct level oftreatment.

Note: For the best results, your fuel supplier shouldtreat the fuel when additives are required. The treatedfuel must meet the requirements that are stated intables 36, 37 and 38.


58 SEBU8311-01Maintenance SectionMaintenance Interval Schedule

i02965846

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 60Battery or Battery Cable - Disconnect .................. 61Engine - Clean ...................................................... 67Engine Air Cleaner Element (Dual Element) -Clean/Replace .................................................... 68Engine Air Cleaner Element (Single Element) -Inspect/Replace .................................................. 70Fuel System - Prime ............................................. 76Severe Service Application - Check ..................... 85

Daily

Cooling System Coolant Level - Check ................ 65Driven Equipment - Check .................................... 67Engine Air Cleaner Service Indicator - Inspect ..... 70Engine Air Precleaner - Check/Clean ................... 71Engine Oil Level - Check ...................................... 72Fuel System Primary Filter/Water Separator -Drain ................................................................... 82Walk-Around Inspection ........................................ 87

Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 83

Every 250 Service Hours or 6 Months

Alternator and Fan Belts - Inspect/Adjust ............. 59

Every 500 Service Hours

Fuel System Filter - Replace ................................ 80

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 61Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 66Engine Air Cleaner Element (Dual Element) -Clean/Replace .................................................... 68Engine Air Cleaner Element (Single Element) -Inspect/Replace .................................................. 70Engine Oil and Filter - Change ............................. 73Hoses and Clamps - Inspect/Replace .................. 83Radiator - Clean .................................................... 84


Alternator and Fan Belts - Replace ....................... 60Engine Valve Lash - Inspect/Adjust ...................... 74Turbocharger - Inspect .......................................... 86


Alternator - Inspect ............................................... 59

Engine Crankcase Breather - Replace ................. 71Engine Mounts - Inspect ....................................... 72Starting Motor - Inspect ........................................ 86


Fuel Injector - Test/Change ................................... 75Water Pump - Inspect ........................................... 88

Every 6000 Service Hours or 3 Years

Cooling System Coolant (Commercial Heavy-Duty) -Change ............................................................... 62Cooling System Coolant Extender (ELC) - Add .... 65

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 63


SEBU8311-01 59Maintenance SectionAlternator - Inspect

i02322311

Alternator - Inspect

Perkins recommends a scheduled inspection ofthe alternator. Inspect the alternator for looseconnections and correct battery charging. Check theammeter (if equipped) during engine operation inorder to ensure correct battery performance and/orcorrect performance of the electrical system. Makerepairs, as required.

Check the alternator and the battery charger forcorrect operation. If the batteries are correctlycharged, the ammeter reading should be very nearzero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power. If the battery is too cold,the battery will not crank the engine. When theengine is not run for long periods of time or if theengine is run for short periods, the batteries may notfully charge. A battery with a low charge will freezemore easily than a battery with a full charge.

i02665597

Alternator and Fan Belts -Inspect/Adjust

InspectionTo maximize the engine performance, inspect thebelts for wear and for cracking. Replace belts that areworn or damaged.

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.The additional load on the new belt could cause thenew belt to break.

If the belts are too loose, vibration causesunnecessary wear on the belts and pulleys. Loosebelts may slip enough to cause overheating.

To accurately check the belt tension, a suitable gaugeshould be used.

g01003936Illustration 31Typical example(1) Burroughs Gauge

Install the gauge (1) at the center of the belt betweenthe alternator and the crankshaft pulley and checkthe belt tension. The correct tension for a new belt is400 N (90 lb) to 489 N (110 lb). The correct tensionfor a used belt that has been in operation for 30minutes or more at the rated speed is 267 N (60 lb)to 356 N (80 lb).

If twin belts are installed, check and adjust thetension on both belts.

Adjustment


Typical example(1) Adjusting bolt(2) Mounting bolts

1. Loosen mounting bolts (2) and adjusting bolt (1).


60 SEBU8311-01Maintenance SectionAlternator and Fan Belts - Replace

2. Move the alternator in order to increase ordecrease the belt tension.

3. Tighten adjusting bolt (1). Tighten mounting bolts(2). Refer to the Specifications Manual for thecorrect torque settings.

i02166560

Alternator and Fan Belts -Replace


(1) Adjusting bolt(2) Mounting bolts

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.The additional load on the new belt could cause thenew belt to break.

Note: When new belts are installed, check the belttension again after 20 hours of engine operation.

Refer to the Disassembly and Assembly Manual forthe installation procedure and the removal procedurefor the belt.

i02322315

Battery - Replace

Batteries give off combustible gases which canexplode. A spark can cause the combustible gas-es to ignite. This can result in severe personal in-jury or death.

Ensure proper ventilation for batteries that are inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Switch the engine to the OFF position. Removeall electrical loads.

2. Turn off any battery chargers. Disconnect anybattery chargers.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the NEGATIVE “-” terminalon the starting motor. Disconnect the cable fromthe NEGATIVE “-” battery terminal.

4. The POSITIVE “+” cable connects the POSITIVE“+” battery terminal to the POSITIVE “+” terminalon the starting motor. Disconnect the cable fromthe POSITIVE “+” battery terminal.

Note: Always recycle a battery. Never discard abattery. Dispose of used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure thatthe engine start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE “+” battery terminal.



Battery Electrolyte Level - Check

8. Connect the NEGATIVE “-” cable to the NEGATIVE“-” battery terminal.

i02747977

Battery Electrolyte Level -Check

When the engine is not run for long periods of time orwhen the engine is run for short periods, the batteriesmay not fully recharge. Ensure a full charge in orderto help prevent the battery from freezing. If batteriesare correctly charged, the ammeter reading shouldbe very near zero, when the engine is in operation.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the “FULL” mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.

2. Check the condition of the electrolyte with asuitable battery tester.

3. Install the caps.

4. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• Use a solution of 0.1 kg (0.2 lb) baking sodaand 1 L (1 qt) of clean water.

• Use a solution of ammonium hydroxide.

Thoroughly rinse the battery case with clean water.

i02323088

Battery or Battery Cable -Disconnect

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Disconnect the negative battery terminal. Ensurethat the cable cannot contact the terminal. Whenfour 12 volt batteries are involved, two negativeconnection must be disconnected.

3. Remove the positive connection.

4. Clean all disconnected connection and batteryterminals.

5. Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fitcorrectly. Coat the clamps and the terminals witha suitable silicone lubricant or petroleum jelly.

6. Tape the cable connections in order to helpprevent accidental starting.

7. Proceed with necessary system repairs.

8. In order to connect the battery, connect thepositive connection before the negative connector.


62 SEBU8311-01Maintenance SectionCooling System Coolant (Commercial Heavy-Duty) - Change

i02595666

Cooling System Coolant(Commercial Heavy-Duty) -Change

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Dispose of all fluids according to Local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

Note: When the cooling system is cleaned, onlyclean water is needed.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.


Typical example

2. Open the drain cock or remove the drain plug (1)on the engine. Open the drain cock or remove thedrain plug on the radiator.

Allow the coolant to drain.

NOTICEDispose of used engine coolant or recycle. Variousmethods have been proposed to reclaim used coolantfor reuse in engine cooling systems. The full distillationprocedure is the only method acceptable by Perkins toreclaim the coolant.

For information regarding the disposal and therecycling of used coolant, consult your Perkins dealeror your Perkins distributor.

Flush1. Flush the cooling system with clean water in orderto remove any debris.

2. Close the drain cock or install the drain plug in theengine. Close the drain cock or install the drainplug on the radiator.

NOTICEDo not fill the cooling system faster than 5 L(1.3 US gal) per minute to avoid air locks.

Cooling system air locksmay result in engine damage.



Cooling System Coolant (ELC) - Change

3. Fill the cooling system with clean water. Install thecooling system filler cap.

4. Start and run the engine at low idle until thetemperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the drain cock or removethe drain plug on the engine. Open the drain cockor remove the drain plug on the radiator. Allowthe water to drain. Flush the cooling system withclean water.

Fill1. Close the drain cock or install the drain plug on theengine. Close the drain cock or install the drainplug on the radiator.



2. Fill the cooling system with CommercialHeavy-Duty Coolant. Add Supplemental CoolantAdditive to the coolant. For the correct amount,refer to the Operation and Maintenance Manual,“Fluid Recommendations” topic (MaintenanceSection) for more information on cooling systemspecifications. Do not install the cooling systemfiller cap.

3. Start and run the engine at low idle. Increase theengine rpm to high idle. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

4. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level in theexpansion bottle (if equipped) at the correct level.

5. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket that is on the cooling system filler capis not damaged, use a suitable pressurizing pumpin order to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a newcooling system filler cap.

6. Start the engine. Inspect the cooling system forleaks and for correct operating temperature.

i02595733

Cooling System Coolant (ELC)- Change


Dispose of all fluids according to Local regulations andmandates.



Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

Note: When the cooling system is cleaned, onlyclean water is needed when the ELC is drained andreplaced.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe hoses, if necessary.


64 SEBU8311-01Maintenance SectionCooling System Coolant (ELC) - Change

Drain


1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.


2. Open the drain cock or remove the drain plug (1)on the engine. Open the drain cock or remove thedrain plug on the radiator.

Allow the coolant to drain.

NOTICEDispose of used engine coolant or recycle. Variousmethods have been proposed to reclaim used coolantfor reuse in engine cooling systems. The full distillationprocedure is the only method acceptable by Perkins toreclaim the coolant.

For information regarding the disposal and therecycling of used coolant, consult your Perkins dealeror your Perkins distributor.

Flush1. Flush the cooling system with clean water in orderto remove any debris.

2. Close the drain cock or install the drain plug in theengine. Close the drain cock or install the drainplug on the radiator.



3. Fill the cooling system with clean water. Install thecooling system filler cap.

4. Start and run the engine at low idle until thetemperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the drain cock or removethe drain plug on the engine. Open the drain cockor remove the drain plug on the radiator. Allowthe water to drain. Flush the cooling system withclean water.

Fill1. Close the drain cock or install the drain plug on theengine. Close the drain cock or install the drainplug on the radiator.



2. Fill the cooling system with Extended LifeCoolant (ELC). Refer to the Operation andMaintenance Manual, “Fluid Recommendations”topic (Maintenance Section) for more informationon cooling system specifications. Do not install thecooling system filler cap.

3. Start and run the engine at low idle. Increase theengine rpm to high idle. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

4. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level in theexpansion bottle (if equipped) at the correct level.



Cooling System Coolant Extender (ELC) - Add

5. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket that is on the cooling system filler capis not damaged, use a suitable pressurizing pumpin order to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a newcooling system filler cap.

6. Start the engine. Inspect the cooling system forleaks and for correct operating temperature.

i02335364

Cooling System CoolantExtender (ELC) - Add

The Perkins Extended Life Coolant (ELC) does notneed the frequent addition of Supplemental CoolantAdditives (SCA) that are associated with conventionalcoolants. The Extender only needs to be added once.

Check the cooling system only when the engine isstopped and cool.

1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. It may be necessary to drain enough coolant fromthe cooling system in order to add the Extender.

3. Add Extender according to the requirements foryour engine’s cooling system capacity. Refer tothis Operation and Maintenance Manual, “RefillCapacities” in the Maintenance Section for thecapacity of the cooling system for your engine.Refer to this Operation and Maintenance Manual,“Fluid Recommendations” information for thePerkins ELC Extender.

4. Clean the cooling system filler cap and inspect thegasket. If the gasket is damaged, discard the oldfiller cap and install a new filler cap. If the gasketis not damaged, use a suitable pressurizing pumpin order to pressure test the filler cap. The correctpressure is stamped on the face of the filler cap. Ifthe filler cap does not retain the correct pressure,install a new filler cap.

i02335378

Cooling System Coolant Level- Check

Engines With a Coolant RecoveryTankNote: The cooling system may not have beenprovided by Perkins. The procedure that followsis for typical cooling systems. Refer to the OEMinformation for the correct procedures.

Check the coolant level when the engine is stoppedand cool.

1. Observe the coolant level in the coolant recoverytank. Maintain the coolant level to “COLD FULL”mark on the coolant recovery tank.


2. Loosen filler cap slowly in order to relieve anypressure. Remove the filler cap.

3. Pour the correct coolant mixture into the tank.Refer to the Operation and Maintenance Manual,“Refill Capacities and Recommendations” forinformation on the correct mixture and type ofcoolant. Refer to the Operation and MaintenanceManual, “Refill Capacities and Recommendations”for the cooling system capacity. Do not fill thecoolant recovery tank above “COLD FULL” mark.



66 SEBU8311-01Maintenance SectionCooling System Supplemental Coolant Additive (SCA) - Test/Add

4. Clean filler cap and the receptacle. Reinstall thefiller cap and inspect the cooling system for leaks.

Note: The coolant will expand as the coolant heatsup during normal engine operation. The additionalvolume will be forced into the coolant recovery tankduring engine operation. When the engine is stoppedand cool, the coolant will return to the engine.

Engines Without a CoolantRecovery TankCheck the coolant level when the engine is stoppedand cool.


Cooling system filler cap


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the correct level in the sight glass.


4. Inspect the cooling system for leaks.

i02335389

Cooling System SupplementalCoolant Additive (SCA) -Test/Add

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and the eyes. Do not drink cooling systemcoolant additive.

Test for SCA Concentration

Heavy-Duty Coolant/Antifreeze and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Use a Coolant Conditioner Test Kit in order to checkthe concentration of the SCA.

Add the SCA, If Necessary

NOTICEDo not exceed the recommended amount of sup-plemental coolant additive concentration. Excessivesupplemental coolant additive concentration can formdeposits on the higher temperature surfaces of thecooling system, reducing the engine’s heat transfercharacteristics. Reduced heat transfer could causecracking of the cylinder head and other high temper-ature components. Excessive supplemental coolantadditive concentration could also result in radiatortube blockage, overheating, and/or accelerated waterpump seal wear. Never use both liquid supplementalcoolant additive and the spin-on element (if equipped)at the same time. The use of those additives togethercould result in supplemental coolant additive concen-tration exceeding the recommended maximum.




Driven Equipment - Check

1. Slowly loosen the cooling system filler cap inorder to relieve the pressure. Remove the coolingsystem filler cap.

Note: Always discard drained fluids according tolocal regulations.

2. If necessary, drain some coolant from the coolingsystem into a suitable container in order to allowspace for the extra SCA.

3. Add the correct amount of SCA. Refer to theOperation and Maintenance Manual, “RefillCapacities and Recommendations” for moreinformation on SCA requirements.


i02151646

Driven Equipment - Check

Refer to the OEM specifications for more informationon the following maintenance recommendations forthe driven equipment:

• Inspection

• Adjustment

• Lubrication

• Other maintenance recommendations

Perform any maintenance for the driven equipmentwhich is recommended by the OEM.

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Engine - Clean

Personal injury or death can result from high volt-age.

Moisture can create paths of electrical conductiv-ity.

Make sure that the electrical system is OFF. Lockout the starting controls and tag the controls “DONOT OPERATE”.

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Periodic cleaning of the engine is recommended.Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

Note: Caution must be used in order to preventelectrical components from being damaged byexcessive water when the engine is cleaned.Pressure washers and steam cleaners should not bedirected at any electrical connectors or the junction ofcables into the rear of the connectors. Avoid electricalcomponents such as the alternator, and the starter.Protect the fuel injection pump from fluids in orderto wash the engine.


68 SEBU8311-01Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

i02736653

Engine Air Cleaner Element(Dual Element) - Clean/Replace

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Servicing the Air Cleaner ElementsIf the air cleaner element becomes plugged, the aircan split the material of the air cleaner element.Unfiltered air will drastically accelerate internalengine wear. Your Perkins dealer has the proper aircleaner elements for your application. Consult yourPerkins dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

• Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleanerelement.

• The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

• The air cleaner element should be replaced at leastone time per year. This replacement should beperformed regardless of the number of cleanings.

Replace the dirty paper air cleaner elements withclean air cleaner elements. Before installation, theair cleaner elements should be thoroughly checkedfor tears and/or holes in the filter material. Inspectthe gasket or the seal of the air cleaner element fordamage. Maintain a supply of suitable air cleanerelements for replacement purposes.

Dual Element Air Cleaners

The dual element air cleaner contains a primaryair cleaner element and a secondary air cleanerelement. The primary air cleaner element can beused up to six times if the element is properly cleanedand inspected. The primary air cleaner elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

The secondary air cleaner element is not serviceableor washable. The secondary air cleaner elementshould be removed and discarded for every threecleanings of the primary air cleaner element. Whenthe engine is operating in environments that aredusty or dirty, air cleaner elements may require morefrequent replacement.


(1) Cover(2) Primary air cleaner element(3) Secondary air cleaner element(4) Turbocharger air inlet

1. Remove the cover. Remove the primary aircleaner element.

2. The secondary air cleaner element should beremoved and discarded for every three cleaningsof the primary air cleaner element.

Note: Refer to “Cleaning the Primary Air CleanerElements”.

3. Cover the turbocharger air inlet with tape in orderto keep dirt out.

4. Clean the inside of the air cleaner cover and bodywith a clean, dry cloth.

5. Remove the tape for the turbocharger air inlet.Install the secondary air cleaner element. Install aprimary air cleaner element that is new or cleaned.

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.



Engine Air Cleaner Element (Dual Element) - Clean/Replace

Cleaning the Primary Air CleanerElements

NOTICEPerkins recommends certified air filter cleaning ser-vices that are available at Perkins dealers. ThePerkins cleaning process uses proven procedures toassure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary air cleaner element can be used upto six times if the element is properly cleaned andinspected. When the primary air cleaner element iscleaned, check for rips or tears in the filter material.The primary air cleaner element should be replacedat least one time per year. This replacement shouldbe performed regardless of the number of cleanings.

Use clean primary air cleaner elements while dirtyelements are being cleaned.

NOTICEDo not clean the air cleaner elements by bumping ortapping. This could damage the seals. Do not use el-ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air cleaner elementsbefore cleaning. Inspect the air cleaner elements fordamage to the seal, the gaskets, and the outer cover.Discard any damaged air cleaner elements.

There are two common methods that are used toclean primary air cleaner elements:

• Pressurized air

• Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary aircleaner elements that have not been cleaned morethan two times. Pressurized air will not removedeposits of carbon and oil. Use filtered, dry air with amaximum pressure of 207 kPa (30 psi).


Note: When the primary air cleaner elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element. Dirtcould be forced further into the pleats.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningprimary air cleaner elements which require dailycleaning because of a dry, dusty environment.Cleaning with pressurized air is recommended priorto vacuum cleaning. Vacuum cleaning will not removedeposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air CleanerElements”.


70 SEBU8311-01Maintenance SectionEngine Air Cleaner Element (Single Element) - Inspect/Replace

Inspecting the Primary Air CleanerElements


Inspect the clean, dry primary air cleaner element.Use a 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air cleanerelement. Rotate the primary air cleaner element.Inspect the primary air cleaner element for tearsand/or holes. Inspect the primary air cleaner elementfor light that may show through the filter material. If itis necessary in order to confirm the result, comparethe primary air cleaner element to a new primary aircleaner element that has the same part number.

Do not use a primary air cleaner element that hasany tears and/or holes in the filter material. Do notuse a primary air cleaner element with damagedpleats, gaskets or seals. Discard damaged primaryair cleaner elements.

Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes inspectionwill not be used, the primary air cleaner element canbe stored for future use.


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An air flow restrictionmay result. To protect against dirt and damage, wrapthe primary air cleaner elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside ofthe box and mark the primary air cleaner element.Include the following information:

• Date of cleaning

• Number of cleanings

Store the box in a dry location.

i02152042

Engine Air CleanerElement (Single Element) -Inspect/Replace

Refer to Operation and Maintenance Manual, “EngineAir Cleaner Service Indicator-Inspect”.

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

A wide variety of air cleaners may be installed for usewith this engine. Consult the OEM information for thecorrect procedure to replace the air cleaner.

i02335405

Engine Air Cleaner ServiceIndicator - Inspect

Some engines may be equipped with a differentservice indicator.



Engine Air Precleaner - Check/Clean

Some engines are equipped with a differential gaugefor inlet air pressure. The differential gauge for inletair pressure displays the difference in the pressurethat is measured before the air cleaner element andthe pressure that is measured after the air cleanerelement. As the air cleaner element becomes dirty,the pressure differential rises. If your engine isequipped with a different type of service indicator,follow the OEM recommendations in order to servicethe air cleaner service indicator.

The service indicator may be mounted on the aircleaner element or in a remote location.


Typical service indicator

Observe the service indicator. The air cleanerelement should be cleaned or the air cleaner elementshould be replaced when one of the followingconditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service IndicatorService indicators are important instruments.

• Check for ease of resetting. The service indicatorshould reset in less than three pushes.

• Check the movement of the yellow core whenthe engine is accelerated to the engine ratedspeed. The yellow core should latch at the greatestvacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the hole for the serviceindicator may be restricted.

The service indicator may need to be replacedfrequently in environments that are severely dusty.

i02927289

Engine Air Precleaner -Check/Clean


Typical engine air precleaner(1) Wing nut(2) Cover(3) Body

Remove wing nut (1) and cover (2). Check for anaccumulation of dirt and debris in body (3). Clean thebody, if necessary.

After cleaning the precleaner, install cover (2) andwing nut (1).

Note: When the engine is operated in dustyapplications, more frequent cleaning is required.

i02657627

Engine Crankcase Breather -Replace




72 SEBU8311-01Maintenance SectionEngine Mounts - Inspect


Typical example

(1) Screws for the breather cover(2) Breather cover(3) Spring(4) Diaphragm and plate(5) Spacer for turbocharged engines only(6) Joint for turbocharged engines only(7) Cavity(8) Vent hole

1. Loosen the screws (1) and remove the breathercover (2) from the valve mechanism cover.

2. Remove the spring (3). Remove the diaphragmand plate (4).

3. For turbocharged engines, remove the spacer (5)and the joint (6).

4. Clean the vent hole (8) and the cavity (7) in thevalve mechanism cover.

NOTICEMake sure that the components of the breather as-sembly are installed correctly. Engine damage mayoccur if the breather assembly is not working correctly.

5. For turbocharged engines, install a new joint (6)and the spacer (5).

6. Install a new diaphragm and plate (4) for thebreather assembly into the cavity (7) of thevalve mechanism cover or the spacer (5) forturbocharged engines.

7. Install a new spring (3).

8. Install the breather cover (2) and the four screws(1). Tighten the screws.

i02323089

Engine Mounts - Inspect

Note: The engine mounts may not have beensupplied by Perkins. Refer to the OEM informationfor further information on the engine mounts and thecorrect bolt torque.

Inspect the engine mounts for deterioration and forcorrect bolt torque. Engine vibration can be causedby the following conditions:

• Incorrect mounting of the engine

• Deterioration of the engine mounts

• Loose engine mounts

Any engine mount that shows deterioration shouldbe replaced. Refer to the OEM information for therecommended torques.

i02153660

Engine Oil Level - Check

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

g00110310Illustration 45(Y) “ADD” mark. (X) “FULL” mark.



Engine Oil and Filter - Change

NOTICEPerform this maintenance with the engine stopped.

1. Maintain the oil level between “ADD” mark (Y) and“FULL” mark (X) on oil level gauge (1). Do not fillthe crankcase above “FULL” mark (X).

NOTICEOperating your engine when the oil level is above the“FULL” mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oil’s lubricating char-acteristics and could result in the loss of power.

2. Remove the oil filler cap and add oil, if necessary.Clean the oil filler cap. Install the oil filler cap.

i02610655

Engine Oil and Filter - Change

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.





Do not drain the oil when the engine is cold. As the oilcools, suspended waste particles settle on the bottomof the oil pan. The waste particles are not removedwith the draining cold oil. Drain the crankcase withthe engine stopped. Drain the crankcase with theoil warm. This draining method allows the wasteparticles that are suspended in the oil to be drainedcorrectly.

Failure to follow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new oil.

Drain the Engine OilAfter the engine has been run at the normal operatingtemperature, stop the engine. Use one of thefollowing methods to drain the engine crankcase oil:

• If the engine is equipped with a drain valve, turn thedrain valve knob counterclockwise in order to drainthe oil. After the oil has drained, turn the drain valveknob clockwise in order to close the drain valve.

• If the engine is not equipped with a drain valve,remove the oil drain plug in order to allow the oil todrain. After the oil has drained, the oil drain plugshould be cleaned and installed.

Replace the Oil Filter

NOTICEPerkins oil filters are built to Perkins specifications.Use of an oil filter not recommended by Perkins couldresult in severe engine damage to the engine bear-ings, crankshaft, etc., as a result of the larger wasteparticles from unfiltered oil entering the engine lubri-cating system. Only use oil filters recommended byPerkins.

1. Remove the oil filter with a suitable tool.

Note: The following actions can be carried out aspart of the preventive maintenance program.

2. Cut the oil filter open with a suitable tool. Breakapart the pleats and inspect the oil filter for metaldebris. An excessive amount of metal debris inthe oil filter may indicate early wear or a pendingfailure.

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are found inthe oil filter element. Ferrous metals may indicatewear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris inthe oil filter. Consult your Perkins dealer or yourPerkins distributor in order to arrange for a furtheranalysis if an excessive amount of debris is foundin the oil filter.


74 SEBU8311-01Maintenance SectionEngine Valve Lash - Inspect/Adjust

g01334593Illustration 46(1) Oil cooler(2) Adapter(3) Oil filter

Note: The oil cooler (1) and the adapter (2) areinstalled on engines that have a turbocharger.

3. Clean the sealing surface of the cylinder block orthe oil cooler (1).

4. Apply clean engine oil to the new oil filter seal (3).

NOTICEDo not fill the oil filters with oil before installing them.This oil would not be filtered and could be contaminat-ed. Contaminated oil can cause accelerated wear toengine components.

5. Install the oil filter. Tighten the oil filter by hand. Donot overtighten the oil filter.

Fill the Engine Crankcase1. Remove the oil filler cap. Refer to the Operationand Maintenance Manual for more information onlubricant specifications. Fill the crankcase with thecorrect amount of oil. Refer to the Operation andMaintenance Manual for more information on refillcapacities.

NOTICEIf equipped with an auxiliary oil filter system or a re-mote oil filter system, follow the OEM or filter manu-facturer’s recommendations. Under filling or overfillingthe crankcase with oil can cause engine damage.

NOTICETo prevent crankshaft bearing damage, crank the en-gine with the fuel OFF. This will fill the oil filters beforestarting the engine. Do not crank the engine for morethan 30 seconds.

2. Start the engine and run the engine at “LOWIDLE” for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain back tothe sump for a minimum of ten minutes.


Typical example

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the “MIN”and “MAX” marks on the oil level gauge.

i02676023

Engine Valve Lash -Inspect/Adjust

This maintenance is recommended by Perkins aspart of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife. The maintenance for the valve lash is importantin order to keep the engine compliant.

NOTICEOnly qualified service personel should perform thismaintenance. Refer to the Service Manual or your au-thorized Perkins dealer or your Perkins distributor forthe complete valve lash adjustment procedure.

Operation of Perkins engines with incorrect valve lashcan reduce engine efficiency, and also reduce enginecomponent life.



Fuel Injector - Test/Change

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuringthe valve lash. The engine valve lash can beinspected and adjusted when the temperature of theengine is hot or cold.

Refer to Systems Operation, Testing and Adjusting,“Engine Valve Lash - Inspect/Adjust” for moreinformation.

i02154268

Fuel Injector - Test/Change

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

Make sure that you wear eye protection at alltimes during testing. When fuel injection nozzlesare tested, test fluids travel through the orificesof the nozzle tip with high pressure. Under thisamount of pressure, the test fluid can pierce theskin and cause serious injury to the operator.Always keep the tip of the fuel injection nozzlepointed away from the operator and into the fuelcollector and extension.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

Regular maintenance of the fuel injectors isrecommended by Perkins. The fuel injectors mustbe removed and tested by an authorized agent. Thefuel injectors should not be cleaned as cleaning withincorrect tools can damage the nozzle. The fuelinjectors should be renewed only if a fault with thefuel injectors occurs. Some of the problems that mayindicate that new fuel injectors are needed are listedbelow:

• The engine will not start or the engine is difficultto start.

• Not enough power

• The engine misfires or the engine runs erratically.

• High fuel consumption

• Black exhaust smoke

• The engine knocks or there is vibration in theengine.

• Excessive engine temperature

For further information on the removal and theinstallation of the fuel injectors, refer to theDisassembly and Assembly manual.

For further information on the testing of fuel injectors,refer to the Testing and Adjusting manual.

Identification of a suspect FuelInjector

Work carefully around an engine that is running.Engine parts that are hot, or parts that are moving,can cause personal injury.

NOTICEIf your skin comes into contact with high pressure fuel,obtain medical assistence immediately.

NOTICEIf a fuel injector is suspected of operating outside ofnormal parameters it should be removed by a qualifiedtechnician. The suspect fuel injector should be takento an authorised agent for inspection.


76 SEBU8311-01Maintenance SectionFuel System - Prime

Operate the engine at a fast idle speed in order toidentify the faulty fuel injector. Individually loosenand tighten the union nut for the high pressure pipeto each fuel injector. Do not loosen the union nutmore than half a turn. There will be little effect on theengine speed when the union nut to the faulty fuelinjector is loosened.

Consult your authorized Perkins dealer or yourPerkins distributor for further assistance.

i02596360

Fuel System - Prime

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.


Use the following procedure in order to prime the fuelsystem:

If air enters the fuel system, the air must be purgedfrom the fuel system before the engine can bestarted. Air can enter the fuel system when thefollowing events occur:

• The fuel tank is empty or the fuel tank has beenpartially drained.

• The low pressure fuel lines are disconnected.

• A leak exists in the low pressure fuel system.

• The fuel filter is replaced.



Primary filterEnsure that the air is removed from the primary filterbefore you prime the fuel filters. Refer to illustration48.

g01316878Illustration 48This filter may not be installed on the engine.

(1) Vent screws

Fuel filtersThere are three types of fuel filter that may beinstalled on the engine.

• Element

• Canister

• Spin-on filter with fuel priming pump


SEBU8311-01 77Maintenance SectionFuel System - Prime

g01327360Illustration 49Element

(2) Fuel valve(3) Vent screw

g01327361Illustration 50Canister

(4) Vent screw

g01327363Illustration 51Spin-on filter with fuel priming pump

(5) Vent screw

Vent screw (3) is installed on the filter that has anelement. Vent screw (4) is installed on the fuel filterthat has a canister. Vent screw (5) is installed on thespin-on filter.

Priming the systemEnsure that the air is removed from the primary filter.Loosen vent screws (1). Refer to illustration 48.Operate the priming pump. When fuel free from airflows from the vent screw tighten the vent screw.

Note: Some fuel system will use gravity in order toprime the primary fuel filter. If gravity is used ensurethat the fuel tank is full and that all stop valves in thefuel line are open.

There is four different types of systems that can beinstalled on the engine in order to prime the fuelsystem. Refer to illustration 52.

• Hand priming pump

• In-line hand priming pump

• Electrical priming pump

• Transfer pump that is operated by the startingmotor


78 SEBU8311-01Maintenance SectionFuel System - Prime


(6) Hand priming pump(7) In-line priming pump

(8) Electrical priming pump(9) Fuel transfer pump

g01304597Illustration 53(10) Connector bolt (11) Fuel return line (12) Connector bolt

Hand Priming Pump 6

In order to identify the hand priming pump, refer toillustration 52.

1. Ensure that fuel valve (2) for the fuel filter thathas an element is in the ON position. Refer toillustration 49.

2. Loosen vent screw (3 4 or 5) on the fuel filter.


SEBU8311-01 79Maintenance SectionFuel System - Prime

3. Operate hand priming pump (6). When fuel freefrom air flows from the vent screw tighten the ventscrew.

4. Loosen connection (10 or 12) at the fuel injectionpump. Refer to illustration 53.

Note: Fuel return line (11) may need to be removedin order to prime the fuel system.

5. Operate the hand priming pump. When fuel freefrom air flows from the connections tighten theconnecting bolt.

6. The engine should now be able to start. Operatethe starting motor in order to start the engine.

Note: Do not operate the starting motor for morethan 15 seconds. If the engine does not start after 15seconds, stop and wait for 30 seconds before tryingagain.

In-line Priming Pump 7

In order to identify the in-line priming pump, refer toillustration 52.



3. Operate in-line priming pump (7). When fuel freefrom air flows from the vent screw tighten the ventscrew.



5. Operate the in-line priming pump. When fuel freefrom air flows from the connections tighten theconnecting bolt.



Electrical Priming Pump 8

In order to identify the electrical priming pump, referto illustration 52.



3. Operate electrical priming pump (8). When fuelfree from air flows from the vent screw tighten thevent screw. Switch off the electrical priming pump.



5. Operate the in-line priming pump. When fuel freefrom air flows from the connections tighten theconnecting bolt.



Fuel Transfer Pump 9

In order to identify the fuel transfer pump, refer toillustration 52.

Note: In order to use the transfer pump, you mustoperate the starting motor. Do not operate the startingmotor for more than 15 seconds. After 15 seconds,stop and wait for 30 seconds before operating thestarting motor.



3. Operate fuel transfer pump (9). When fuel freefrom air flows from the vent screw tighten the ventscrew. Stop the fuel transfer pump.



5. Operate the fuel transfer pump. When fuel freefrom air flows from the connections tighten theconnecting bolt. Stop the transfer pump.



80 SEBU8311-01Maintenance SectionFuel System Filter - Replace


i02608681

Fuel System Filter - Replace

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.



Fuel Filter with Canister1. Close the fuel supply valve.


2. Clean the outside of the fuel filter assembly (1).

3. Remove setscrew (2).

4. Remove the canister (3). Ensure that any fluid isdrained into a suitable container.


5. Assemble the following items: seals (8), seal (7),canister (3), and bowl (10). Place washer (5) andseal (6) on setscrew (2).

6. Fasten the assembly to the fuel filter base withsetscrew (2).



Fuel System Filter - Replace

The fuel system will need to be primed after thenew filter is installed. Refer to this Operation andMaintenance Manual, “Fuel System - Prime”.

Fuel Filter with Element1. Close the fuel supply valve (1).


2. Clean the outside of the fuel filter assembly.

3. Loosen the locking ring (2).

4. Remove the casing (3) for the filter and theelement. Ensure that any fluid is drained into asuitable container.


Typical example

Note: Do not fill the fuel filter with fuel. The fuel willnot be filtered and the fuel could be contaminated.Contaminated fuel can damage your fuel system.

5. Assemble the following items: seal (5), filterelement (6) and casing (3).

6. Install the assembled items to the filter base (4).

7. Install the locking ring (2) to the filter head. Rotatethe locking ring in order to lock the assembly.


Fuel Filter with Priming Pump1. Close the fuel supply valve.

2. Clean the outside of the fuel filter assembly.


82 SEBU8311-01Maintenance SectionFuel System Primary Filter/Water Separator - Drain


3. By using a suitable tool, remove spin-on filter (1).Ensure that any fluid is drained into a suitablecontainer.

Note: Do not fill the fuel filter with fuel. The fuel willnot be filtered and the fuel could be contaminated.Contaminated fuel can damage your fuel system.

4. Install the new spin-on filter. Tighten the spin-onfilter by hand.


i02627223

Fuel System PrimaryFilter/Water Separator - Drain

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

NOTICEThe water separator is not a filter. The water separa-tor separates water from the fuel. The engine shouldnever be allowed to run with the water separator morethan half full. Engine damage may result.


1. Open drain (1). Catch the draining fluid in asuitable container. Dispose of the drained fluidcorrectly.

2. Close drain (1).

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.



Fuel Tank Water and Sediment - Drain

i02335436

Fuel Tank Water and Sediment- Drain



Fuel TankFuel quality is critical to the performance and to theservice life of the engine. Water in the fuel can causeexcessive wear to the fuel system.

Water can be introduced into the fuel tank when thefuel tank is being filled.

Condensation occurs during the heating and coolingof fuel. The condensation occurs as the fuel passesthrough the fuel system and the fuel returns to thefuel tank. This causes water to accumulate in fueltanks. Draining the fuel tank regularly and obtainingfuel from reliable sources can help to eliminate waterin the fuel.

Drain the Water and the SedimentFuel tanks should contain some provision for drainingwater and draining sediment from the bottom of thefuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Check the fuel daily. Allow five minutes after thefuel tank has been filled before draining water andsediment from the fuel tank.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. Ifthe engine is equipped with this system, regularmaintenance of the fuel system filter is important.

Fuel Storage TanksDrain the water and the sediment from the fuelstorage tank at the following intervals:

• Weekly

• Service intervals

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank.

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from thestorage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i02813964

Hoses and Clamps -Inspect/Replace

Inspect all hoses for leaks that are caused by thefollowing conditions:

• Cracking

• Softness

• Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque. Do not clip any other item to thehigh pressure lines.

Check for the following conditions:


84 SEBU8311-01Maintenance SectionRadiator - Clean

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in placeof any standard hose clamp. Ensure that the constanttorque hose clamp is the same size as the standardclamp.

Due to extreme temperature changes, the hose willharden. Hardening of the hoses will cause hoseclamps to loosen. This can result in leaks. A constanttorque hose clamp will help to prevent loose hoseclamps.

Each installation application can be different. Thedifferences depend on the following factors:

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the ClampsRefer to the OEM information for further informationon removing and replacing fuel hoses (if equipped).

The coolant system and the hoses for the coolantsystem are not usually supplied by Perkins. Thefollowing text describes a typical method of replacingcoolant hoses. Refer to the OEM information forfurther information on the coolant system and thehoses for the coolant system.


1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system to alevel that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: For the correct coolant, see this Operation andMaintenance Manual, “Fluid Recommendations”.

8. Refill the cooling system. Refer to the OEMinformation for further information on refilling thecooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler cap’s seals. Replace thecooling system filler cap if the seals are damaged.Install the cooling system filler cap.

10.Start the engine. Inspect the cooling system forleaks.

i02335774

Radiator - Clean

The radiator is not usually supplied by Perkins. Thefollowing text describes a typical cleaning procedurefor the radiator. Refer to the OEM information forfurther information on cleaning the radiator.

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.



Severe Service Application - Check

Inspect the radiator for these items: Damaged fins,corrosion, dirt, grease, insects, leaves, oil, and otherdebris. Clean the radiator, if necessary.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionto the fan’s air flow. Hold the nozzle approximately6 mm (0.25 inch) away from the radiator fins. Slowlymove the air nozzle in a direction that is parallel withthe radiator tube assembly. This will remove debristhat is between the tubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

Use a degreaser and steam for removal of oil andgrease. Clean both sides of the core. Wash the corewith detergent and hot water. Thoroughly rinse thecore with clean water.

If the radiator is blocked internally, refer to the OEMManual for information regarding flushing the coolingsystem.

After cleaning the radiator, start the engine. Allowthe engine to operate at low idle speed for three tofive minutes. Accelerate the engine to high idle. Thiswill help in the removal of debris and the drying ofthe core. Slowly reduce the engine speed to low idleand then stop the engine. Use a light bulb behindthe core in order to inspect the core for cleanliness.Repeat the cleaning, if necessary.

Inspect the fins for damage. Bent fins may be openedwith a “comb”. Inspect these items for good condition:Welds, mounting brackets, air lines, connections,clamps, and seals. Make repairs, if necessary.

i02335775

Severe Service Application -Check

Severe service is the application of an engine thatexceeds the current published standards for thatengine. Perkins maintains standards for the followingengine parameters:

• Performance such as power range, speed range,and fuel consumption

• Fuel quality

• Operational Altitude

• Maintenance intervals

• Oil selection and maintenance

• Coolant type and maintenance

• Environmental qualities

• Installation

• The temperature of the fluid in the engine

Refer to the standards for the engine or consult yourPerkins dealer or your Perkins distributor in order todetermine if the engine is operating within the definedparameters.

Severe service operation can accelerate componentwear. Engines that operate under severe conditionsmay need more frequent maintenance intervals inorder to ensure maximum reliability and retention offull service life.

Due to individual applications, it is not possibleto identify all of the factors which can contributeto severe service operation. Consult your Perkinsdealer or your Perkins distributor for the uniquemaintenance that is necessary for the engine.

The operating environment, incorrect operatingprocedures and incorrect maintenance procedurescan be factors which contribute to a severe serviceapplication.


86 SEBU8311-01Maintenance SectionStarting Motor - Inspect

Environmental FactorsAmbient temperatures – The engine may beexposed to extended operation in extremelycold environments or hot environments. Valvecomponents can be damaged by carbon buildup ifthe engine is frequently started and stopped in verycold temperatures. Extremely hot intake air reducesengine performance.

Quality of the air – The engine may be exposedto extended operation in an environment that isdirty or dusty, unless the equipment is cleanedregularly. Mud, dirt and dust can encase components.Maintenance can be very difficult. The buildup cancontain corrosive chemicals.

Buildup – Compounds, elements, corrosivechemicals and salt can damage some components.

Altitude – Problems can arise when the engine isoperated at altitudes that are higher than the intendedsettings for that application. Necessary adjustmentsshould be made.

Incorrect Operating Procedures• Extended operation at low idle

• Frequent hot shutdowns

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application

Incorrect Maintenance Procedures• Extending the maintenance intervals

• Failure to use recommended fuel, lubricants andcoolant/antifreeze

i02177969

Starting Motor - Inspect

Perkins recommends a scheduled inspection of thestarting motor. If the starting motor fails, the enginemay not start in an emergency situation.

Check the starting motor for correct operation. Checkthe electrical connections and clean the electricalconnections. Refer to the Systems Operation, Testingand Adjusting Manual, “Electric Starting System -Test” for more information on the checking procedureand for specifications or consult your Perkins dealeror your Perkins distributor for assistance.

i02184788

Turbocharger - Inspect(If Equipped)

A regular visual inspection of the turbocharger isrecommended. Any fumes from the crankcase arefiltered through the air inlet system. Therefore,by-products from oil and from combustion can collectin the turbocharger compressor housing. Over time,this buildup can contribute to loss of engine power,increased black smoke and overall loss of engineefficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage to theturbocharger compressor wheel can cause additionaldamage to the pistons, the valves, and the cylinderhead.

NOTICETurbocharger bearing failures can cause large quanti-ties of oil to enter the air intake and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of oil into a turbocharger under extend-ed low idle operation should not cause problems aslong as a turbocharger bearing failure has not oc-cured.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is renewed.

A visual inspection of the turbocharger can minimizeunscheduled downtime. A visual inspection of theturbocharger can also reduce the chance for potentialdamage to other engine parts.

Removal and InstallationNote: The turbochargers that are supplied arenonserviceable.



Walk-Around Inspection

For options regarding the removal, installation, andreplacement, consult your Perkins dealer or yourPerkins distributor. Refer to the Disassembly andAssembly Manual, “Turbocharger - Remove andTurbocharger - Install” for further information.

Inspecting

NOTICEThe compressor housing for the turbocharger mustnot be removed from the turbocharger for cleaning.

The actuator linkage is connected to the compressorhousing. If the actuator linkage is moved or disturbedthe engine may not comply with emmissions legisla-tion.

1. Remove the pipe from the turbocharger exhaustoutlet and remove the air intake pipe to theturbocharger. Visually inspect the piping for thepresence of oil. Clean the interior of the pipesin order to prevent dirt from entering duringreassembly.

2. Check for the presence of oil. If oil is leaking fromthe back side of the compressor wheel, there is apossibility of a failed turbocharger oil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence of oilmay also be the result of a restriction of the linefor the intake air (clogged air filters), which causesthe turbocharger to slobber.

3. Inspect the bore of the housing of the turbineoutlet for corrosion.

4. Fasten the air intake pipe and the exhaust outletpipe to the turbocharger housing.

i02177973

Walk-Around Inspection

Inspect the Engine for Leaks andfor Loose ConnectionsA walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connections andtrash buildup. Make repairs, as needed:

• The guards must be in the correct place. Repairdamaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine is a firehazard. Remove the accumulated grease and oil. Re-fer to this Operation and Maintenance Manual, “En-gine - Clean” for more information.

• Ensure that the cooling system hoses are correctlyclamped and that the cooling system hoses aretight. Check for leaks. Check the condition of allpipes.

• Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by thecoolant in the cooling system. It is normal for a smallamount of leakage to occur as the engine cools downand the parts contract.

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removal ofthe water pump and the installation of water pumpand/or seal, refer to the Disassembly and AssemblyManual, “Water Pump - Remove and Install” for moreinformation or consult your Perkins dealer or yourPerkins distributor.

• Inspect the lubrication system for leaks at the frontcrankshaft seal, the rear crankshaft seal, the oilpan, the oil filters and the rocker cover.

• Inspect the fuel system for leaks. Look for loosefuel line clamps and/or tie-wraps.

• Inspect the piping for the air intake system and theelbows for cracks and for loose clamps. Ensurethat hoses and tubes are not contacting otherhoses, tubes, wiring harnesses, etc.

• Inspect the alternator belts and any accessorydrive belts for cracks, breaks or other damage.


88 SEBU8311-01Maintenance SectionWater Pump - Inspect

Belts for multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, the belt willcarry more load than the belts that are not replaced.The older belts are stretched. The additional load onthe new belt could cause the belt to break.

• Drain the water and the sediment from the fueltank on a daily basis in order to ensure that onlyclean fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connection andfor good condition.

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolyte levelof the batteries, unless the engine is equipped witha maintenance free battery.

• Check the condition of the gauges. Replace anygauges that are cracked. Replace any gauge thatcan not be calibrated.

i01907756

Water Pump - Inspect

A failed water pump may cause severe engineoverheating problems that could result in the followingconditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

Note: The water pump seal is lubricated by thecoolant in the cooling system. It is normal for a smallamount of leakage to occur as the engine cools downand parts contract.

Visually inspect the water pump for leaks. Renewthe water pump seal or the water pump if thereis an excessive leakage of coolant. Refer to theDisassembly and Assembly Manual, “Water Pump- Remove and Install” for the disassembly andassembly procedure.


SEBU8311-01 89Warranty Section

Warranty Information

Warranty Section

Warranty Informationi01903596

Emissions WarrantyInformation

This engine may be certified to comply with exhaustemission standards and gaseous emission standardsthat are prescribed by the law at the time ofmanufacture, and this engine may be covered by anEmissions Warranty. Consult your authorized Perkinsdealer or your authorized Perkins distributor in orderto determine if your engine is emissions certified andif your engine is subject to an Emissions Warranty.


90 SEBU8311-01Index Section

Index

A

After Starting Engine ............................................. 32After Stopping Engine............................................ 34Alternator - Inspect ................................................ 59Alternator and Fan Belts - Inspect/Adjust .............. 59Adjustment ......................................................... 59Inspection........................................................... 59

Alternator and Fan Belts - Replace ....................... 60

B

Battery - Replace................................................... 60Battery Electrolyte Level - Check .......................... 61Battery or Battery Cable - Disconnect ................... 61Before Starting Engine ..................................... 11, 30Burn Prevention....................................................... 8Batteries............................................................... 8Coolant................................................................. 8Oils....................................................................... 8

C

Cold Weather Operation........................................ 35Hints for Cold Weather Operation...................... 35Idling the Engine ................................................ 36Recommendations for Coolant Warm Up .......... 36Recommendations for the Coolant .................... 35Viscosity of the Engine Lubrication Oil............... 35

Cooling System Coolant (Commercial Heavy-Duty) -Change ................................................................ 62Drain .................................................................. 62Fill ...................................................................... 63Flush .................................................................. 62

Cooling System Coolant (ELC) - Change.............. 63Drain .................................................................. 64Fill ...................................................................... 64Flush .................................................................. 64

Cooling System Coolant Extender (ELC) - Add..... 65Cooling System Coolant Level - Check ................. 65Engines With a Coolant Recovery Tank............. 65Engines Without a Coolant Recovery Tank........ 66

Cooling System Supplemental Coolant Additive(SCA) - Test/Add.................................................. 66Add the SCA, If Necessary ................................ 66Test for SCA Concentration ............................... 66

Crushing Prevention and Cutting Prevention ........ 10

D

Driven Equipment - Check..................................... 67

E

Electrical System................................................... 12Grounding Practices .......................................... 12

Emergency Stopping ............................................. 34Emissions Certification Film .................................. 24Emissions Warranty Information............................ 89Engine - Clean....................................................... 67Engine Air Cleaner Element (Dual Element) -Clean/Replace ..................................................... 68Cleaning the Primary Air Cleaner Elements ...... 69Servicing the Air Cleaner Elements ................... 68

Engine Air Cleaner Element (Single Element) -Inspect/Replace................................................... 70Engine Air Cleaner Service Indicator - Inspect...... 70Test the Service Indicator................................... 71

Engine Air Precleaner - Check/Clean.................... 71Engine Crankcase Breather - Replace.................. 71Engine Description ................................................ 16Engine Specifications......................................... 17

Engine Identification .............................................. 23Engine Lifting......................................................... 25Engine Mounts - Inspect........................................ 72Engine Oil and Filter - Change .............................. 73Drain the Engine Oil........................................... 73Fill the Engine Crankcase.................................. 74Replace the Oil Filter ......................................... 73

Engine Oil Level - Check....................................... 72Engine Operation................................................... 33Engine Starting ................................................. 11, 30Engine Stopping ............................................... 11, 34Engine Storage...................................................... 25Cooling System.................................................. 26Exhaust System................................................. 27General Items .................................................... 27Induction System ............................................... 26Lubrication System ............................................ 25

Engine Valve Lash - Inspect/Adjust ....................... 74

F

Features and Controls ........................................... 29Fire Prevention and Explosion Prevention .............. 8Fire Extinguisher ................................................ 10Lines, Tubes and Hoses .................................... 10

Fluid Recommendations........................................ 41Engine Oil .......................................................... 42General Lubricant Information ........................... 41

Fluid Recommendations (Coolant Specifications).. 45ELC Cooling System Maintenance .................... 48General Coolant Information.............................. 45

Fluid Recommendations (Fuel Specification) ........ 50Diesel Fuel Characteristics ................................ 52Diesel Fuel Requirements.................................. 50General Information ........................................... 50


SEBU8311-01 91Index Section

Foreword ................................................................. 4California Proposition 65 Warning ....................... 4Literature Information........................................... 4Maintenance ........................................................ 4Maintenance Intervals.......................................... 4Operation ............................................................. 4Overhaul .............................................................. 4Safety................................................................... 4

Fuel and the Effect from Cold Weather ................. 37Fuel Conservation Practices.................................. 33Fuel Injector - Test/Change ................................... 75Identification of a suspect Fuel Injector.............. 75

Fuel Related Components in Cold Weather .......... 38Fuel Filters ......................................................... 38Fuel Heaters ...................................................... 38Fuel Tanks.......................................................... 38

Fuel Shutoff ........................................................... 29Fuel System - Prime.............................................. 76Fuel filters .......................................................... 76Primary filter....................................................... 76Priming the system ............................................ 77

Fuel System Filter - Replace ................................. 80Fuel Filter with Canister ..................................... 80Fuel Filter with Element ..................................... 81Fuel Filter with Priming Pump............................ 81

Fuel System Primary Filter/Water Separator -Drain .................................................................... 82Fuel Tank Water and Sediment - Drain ................. 83Drain the Water and the Sediment..................... 83Fuel Storage Tanks............................................ 83Fuel Tank ........................................................... 83

G

Gauges and Indicators .......................................... 28General Hazard Information .................................... 7Containing Fluid Spillage ..................................... 8Fluid Penetration.................................................. 7Pressure Air and Water........................................ 7

H

Hoses and Clamps - Inspect/Replace ................... 83Replace the Hoses and the Clamps .................. 84

I

Important Safety Information ................................... 2

L

Lifting and Storage ................................................ 25

M

Maintenance Interval Schedule ............................. 58

Maintenance Section............................................. 39Model View Illustrations......................................... 13Model Views .......................................................... 13

O

Operation Section.................................................. 25

P

Product Identification Information .......................... 23Product Information Section .................................. 13

R

Radiator - Clean .................................................... 84Reference Numbers .............................................. 23Record for Reference......................................... 23

Refill Capacities..................................................... 39Cooling System.................................................. 40Lubrication System ............................................ 39

S

Safety Messages..................................................... 5(A) Universal Warning.......................................... 5

Safety Section ......................................................... 5Serial Number Plate .............................................. 23Severe Service Application - Check ...................... 85Environmental Factors ....................................... 86Incorrect Maintenance Procedures .................... 86Incorrect Operating Procedures......................... 86

Starting Motor - Inspect ......................................... 86Starting the Engine................................................ 30Starting with Jump Start Cables ............................ 31Stopping the Engine .............................................. 34

T

Table of Contents..................................................... 3Turbocharger - Inspect (If Equipped)..................... 86Inspecting........................................................... 87Removal and Installation.................................... 86

W

Walk-Around Inspection ........................................ 87Inspect the Engine for Leaks and for LooseConnections ..................................................... 87

Warranty Information ............................................. 89Warranty Section ................................................... 89Water Pump - Inspect ............................................ 88


92 SEBU8311-01Index Section


Product and Dealer InformationNote: For product identification plate locations, see the section “Product Identification Information” in the Operationand Maintenance Manual.

Delivery Date:

Product InformationModel:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer InformationName: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:


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Perkins 400D Owners Manual